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Introduction
In order to address the above stated issues, the voltage regulator systems
must be power factor corrected, high efficient and with less total
harmonic distortion.
Adding active Power Factor Correction in AC voltage regulators
found to have not been addressed.
Power
Factor left
un-corrected
Input voltage and current waveforms without PFC. The voltage waveform is a sine wave
and the current waveform is a pulse or spike. PF<1(0.65 or less for SMPS loads in general)
Power
Factor
corrected
Voltage and current waveforms are sinusoidal and in phase. PF= 0.99
M.S.Ramaiah School of Advanced Studies
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Literature Review
Kuo- Kai Shyu, Ming-Ji Yang, Jing-Heng Hong and Bau- Hung Lin(2004) present a conference paper
on Automatic Voltage Regulator Using a novel Phase shifted PWM is proposed. This system uses a
bulky transformer for series voltage compensation. This method doesnt operate for wide AC input.
This method doesnt address the PFC, hence doesnt address the bulky EMI filter components and
Total Harmonic Distortions.
(Dong-Hee Lee, Jin-Woo Ahn, and Tae-Won Chun(2007) presented variable gain control scheme of
digital automatic voltage regulator for AC brushless generator.
a PID controller with a simple gain adjustor is used. And the gains of PID controller are updated by
the terminal voltage and load current in order to improve dynamic response and stability. The structure
of the proposed gain adjustor is designed by a simple linear function and the gain is increased inproportional to load current and terminal voltage.
Hamdy Ahmed Ashour(2004) presented a new electronic voltage stabilizer topology utilizes four
AC switches in a form that may be named as "AC H-bridge connection, and based on pulse width
modulation (PWM) AC chopper combined with a single low power compensating transformer.
Such topology eliminates the need of the main input multi-tapping transformer, hence
reducing the overall size, weight and cost.
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Literature Summary
Most of the existing solutions support different input voltages, collectively from 160250VAC range and do not support wide universal AC input (85 -265VAC) range.
Literature reviews refer to poor regulated output voltage i.e. voltages between 200 240VAC.
Literature review papers based solutions cut out the power if AC input is out of 160
250VAC range, which will trip the connected equipments.
Most of the solutions use line frequency transformer, which increases weight and
overall cost of the system.
None of the existing voltage stabilizers provide Power factor correction, hence causes
high electricity bill and PF penalty as well, reduce overall efficiency.
Some systems use tap change techniques to regulate the voltage, which interrupt the
output voltage momentarily and that can reset/trips the computer or other electronics
equipments.
None of the papers presented on regulators support for universal voltage (85 to
265VAC) and do not provide PFC.
In this case all load equipments should have its PFC correction taking place within.
The solutions presented are specific to some countries; they do not work in different
geographic regions.
M.S.Ramaiah School of Advanced Studies
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220V+/- 1%
50Hz
0.99
>93% @ full load
Output:
AC output Voltage
AC output frequency
Power Factor
Efficiency
Protection Features:
<85VAC, >265VAC
up to 300% of rated power for <0.5sec
Yes
Yes
Forced Cooling
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Power Triangle
M.S.Ramaiah School of Advanced Studies
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Active PFC
The preferable type of PFC since it provides more efficient power frequency.
Because Active PFC uses a circuit to correct power factor, Active PFC is able
to generate a theoretical power factor of over 0.95
Active Power Factor Correction also markedly diminishes total harmonics,
automatically corrects for AC input voltage, and is capable of a full range of
input voltage.
Since Active PFC is the more complex method of Power Factor Correction, it
is expensive to produce an Active PFC power supply.
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Conventional Active
PFC
<3000W
Normal
High
High
High
Low (<85%)
Interleaved Active
PFC
>3000W
Low
Low
Low
Low
Normal to High (>94%)
Simulation Parameters
Parameters
Vin
Vout
Pout
Fsw
Cout
L
Conventional Active
PFC
220+/-5%
400V+/-5%
Up to 3000W
100kHz
3300uF
270uH
Interleaved Active
PFC
220+/-5%
400V+/-5%
>3000W
50kHz
3300uF
270uH
Components Comparison
Parameters
Main Switch
Fast Diode
Bridge Diode
Inductance
Capacitor
Cost
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Interleaved PFC
In high power applications interleaving PFC stages can
reduce inductor area and reduce output capacitor ripple
current.
This is made possible through the inductor ripple current
cancellation that occurs with interleaving.
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Bridge
Rectifier
EMI Filter
Interleaving
Channel1
FET Driver
Interleaving
Channel2
FET Driver
6W Fly-back
Power Supply
For house
keeping
12V, 0.5A
To supply PFC
controller chip and
FET driver chips
Output
Cap
Bridge O/P
Voltage Sense
Interleaved
PFC
Controller
UCC28070
Interleaving
Current Sense
Channel1
Interleaving
Current Sense
Channel2
PFC Output
Voltage Sense
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Minimum
Typical
Maximum
Units
85
110 or 220
265
344
390
425
30
47
63
Hz
0.95
1000
90
27
120.21
0.95
Efficiency
95%
Pout
1200
Vout
390
Vdc
F-line
50
Hz
85
Vac
0.69
14.12
150000
Hz
29.25
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Cout selection
Cout
Cout selection
Cout
max Cout
20% derated Cout
ESRmax selection
ESRmax
MOSFET selection
Ipft(flat top)
Ipft
Ipeak
Ipeak
Prds(on)
Estimated AC-DC
Conversion loss
Estimated AC-DC
Conversion loss
Diode Parameters
Idiode
Idiode
Id-peak
(2*Pout*(1/F-line))/(Vout^2-(Vout/2)^2)
421
1/4*(Pout/(Vout*Efficiency*0.637))/
(Vripple*0.8*3.141*fLine)
346
421
657
(Vout-ripple*0.2)/((Pout*Sqrt(2))/(Vinmin*efficiency))
0.28
micro Henry
*Based on Hold up
Energy
micro Farad
*Based on output
voltage ripple
micro Farad
micro Farad
micro Farad
Ohms
(Dmax/Efficiency)*((Pout/2)/Vmin-rec)
4.99
( (Pout* sqrt(2))/(2*Vin-min*Efficiency)+(del
Il1/2) )
17.6
Ifet(rms)*Rds(on)
((Pout/Efficiency)-Pout)*0.5
31.58
(Pout)/(2*Vout*Efficiency)
1.62
M.S.Ramaiah School
of Advanced Studies
( (Pout* sqrt(2))/(2*Vin-min*Efficiency)+(del
Il1/2) )
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BUS Voltage
Sense
12W Fly-back
Power Supply
12V, 1A
House Keeping
Power Supplies
for control
circuitry
3.3V, 1A
H-Bridge
Inverter
Switches
Sine wave
LC Filter
C
T
220V AC Relay
& Output
Connector
4
IG BT Drivers
4
5V, 0.5A
Digital
Controller
TMS320F28027
JTAG
Zero Crossing
Detector
M.S.Ramaiah School of Advanced Studies
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Vo= d*Vbus
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Design of Inverter
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Diff Amp
Gain
Vout Rms
Vo,P
k
Vfb,p
k
0.0033112
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220 Vrms
311.08 V
1.0300662
25 V
0.7284768
V
at ADC = Vfb +1.65 (for
Vfb,rms
21 +Ve
V
Cycle)
V at ADC = Vfb -1.65 (for -Ve
Cycle)
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VIfb at
VIfb at
ADC
Rsens
Ifb, Vifb.p Vifb,r ADC (+Ve (-Ve
e
Ifb,pk
rms k
ms
Cycle)
Cycle)
100.00
0.001
0 3.54E-04 0.025 0.035 0.025
1.685
1.615
100.00
0.001
0 7.07E-04 0.05 0.071 0.050
1.721
1.579
100.00
0.001
0 1.06E-03 0.075 0.106 0.075
1.756
1.544
100.00
0.001
0 1.41E-03 0.1 0.141 0.100
1.791
1.509
100.00
0.001
0 1.77E-03 0.125 0.177 0.125
1.827
1.473
100.00
0.001
0 2.12E-03 0.15 0.212 0.150
1.862
1.438
100.00
0.001
0 2.47E-03 0.175 0.247 0.175
1.897
1.403
100.00
0.001
0 2.83E-03 0.2 0.283 0.200
1.933
1.367
100.00
0.001
0 3.18E-03 0.225 0.318 0.225
1.968
1.332
100.00
0.001
0 3.54E-03 0.25 0.354 0.250
2.004
1.297
100.00
0.001
0 3.89E-03 0.275 0.389 0.275
2.039
1.261
100.00
0.001
0 4.24E-03 0.3 0.424 0.300
2.074
1.226
100.00
0.001
0 4.60E-03 0.325 0.460 0.325
2.110
1.190
100.00
0.001
0 4.95E-03 0.35 0.495 0.350
2.145
1.155
100.00
0.001
0 5.30E-03 0.375 0.530 0.375
2.180
1.120
100.00
0.001
0 5.66E-03 0.4 0.566 0.400
2.216
1.084
100.00
0.001
0 6.01E-03 0.425 0.601 0.425
2.251
1.049
100.00
0.001
0 6.36E-03 0.45 0.636 0.450
2.286
1.014
100.00
0.001
0 6.72E-03 0.475 0.672 0.475
2.322
0.978
100.00
0.001
0 7.07E-03 0.5 0.707 0.500
2.357
0.943
100.00
0.001
0 7.42E-03 0.525 0.742 0.525
2.392
0.908
100.00
0.001
0 7.78E-03 0.55 0.778 0.550
2.428
0.872
100.00
0.001
0 8.13E-03 0.575 0.813 0.575
2.463
0.837
100.00
0.001
0 8.48E-03 0.6 0.848 0.600
2.498
0.802
100.00
0.001
0 8.84E-03 0.625 0.884 0.625
2.534
0.766
100.00
0.001
0 9.19E-03 0.65 0.919 0.650
2.569
0.731
100.00
0.001
0 9.54E-03 0.675 0.954 0.675
2.604
0.696
100.00
0.001
0 9.90E-03 0.7 0.990 0.700
2.640
0.660
100.00
Diff Amp CT
Gain
gain
0.250
0.354
1.000
0.500
0.707
1.000
0.750
1.061
1.000
1.000
1.414
1.000
1.250
1.768
1.000
1.500
2.121
1.000
1.750
2.475
1.000
2.000
2.828
1.000
2.250
3.182
1.000
2.500
3.535
1.000
2.750
3.889
1.000
3.000
4.242
1.000
3.250
4.596
1.000
3.500
4.949
1.000
3.750
5.303
1.000
4.000
5.656
1.000
4.250
6.010
1.000
4.500
6.363
1.000
4.750
6.717
1.000
5.000
7.070
1.000
5.250
7.424
1.000
5.500
7.777
1.000
5.750
8.131
1.000
6.000
8.484
1.000
6.250
8.838
1.000
6.500
9.191
1.000
6.750
9.545
1.000
7.000
9.898
1.000
Current Diff
Amp Gain
Iout
Rms
0.0033112
58
4.545455 Vrms
6.4272733
Io,Pk
7V
CT Ratio
0.001
0.0064272
Isense ,pK
73
0.0045454
V
at ADC
= Vfb +1.65 (for 55
+Ve
Isense
,rms
Cycle)
V at ADC = Vfb -1.65 (for -Ve
Cycle)
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12V Supply
Isolated 15V
Supply
Optical Isolator
(HCPL-350)
Isolated 15V
level PWM
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1 Power On Mode:
When the board powered up, it will get into the power on mode first, the
MCU will initialize itself. When the initialization is finished, the system will
transfer to standby mode automatically.
2 Standby Mode:
When the system is in standby mode, all the PWM and Relay are off. The
system is waiting for the command to turn on. Besides, it will detect if the fault
occurs.
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Power ON Mode
Standby Mode
Fault Mode
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Conclusion
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Both PFC and Inverter boards along with PSUs, IGBT drivers, Control
card can be combined into a single PCB.
With single PCB architecture, one common heatsink can be used and all
heat dissipating components can be attached to it. This helps miniaturize
system size.
PFC controller functionality also can be implemented in the same
microcontroller which is used in inverter board as it has enough
peripherals and memory to accomplish the job.
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Project Schedule
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References
1. Kuo- Kai Shyu, Ming-Ji Yang, Jing-Heng Hong and Bau- Hung
Lin(2004), Automatic Voltage Regulator Using a Novel Phase
Shifted PWM Single- Phase Inverter Annual Conference
IEEE, RIYE Electric CO and the National Science Council of
Taiwan, Busan Korea.
2. Dong-Hee Lee, Jin-Woo Ahn, and Tae-Won Chun(2007), A
Variable Gain Control Scheme of Digital Automatic Voltage
Regulator for AC Generator, Dept. of EE & Mechatronics,
Kyungsung University, Busan, Korea.
3. Hamdy Ahmed Ashour, (2005), A New Electronic StepUp/Down Voltage Stabilizer Topology Based On H- Bridge AC
Chopper, Arab Academy for Science and Technology, Dept of
Electrical and Control Engineering, Miami, Alexandria, Egypt.
M.S.Ramaiah School of Advanced Studies
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References
continued
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References
continued
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Thank You
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