Design and Implementation of Three-phase Resonant DC-DC Power Converter for Low-voltage High-current Applications

Abstract

Abstract—The most commonly employed DC power supply in industrial processes, such as chemical electrolysis, aluminum potlines, DC arc furnaces, graphitizing furnaces, copper refining, plasma torches, the starting process of aircraft, the large Hadron collider, and nuclear fusion, is a magnetic confinement approach based on a line frequency isolated transformer with a phase-controlled rectifier. These power supplies suffer from high conduction losses, low efficiency, large size, and heavy weight. In this article, a high-frequency isolated three-phase resonant DC-DC converter is proposed for high power applications that demand low voltage, isolation, good regulation against load and line disturbances, and fast dynamic response. The modeling, control, and design of the proposed converter are carried out under symmetrical control with fixed frequency operation, and its steady-state analysis has been presented according to the description of the operational stages of the converter. Mathematical modeling of the LLC resonant tank network is presented, and its design curves are plotted against a variation of normalized frequency for different values of load. Based on mathematical analysis, a 5-V/150-A prototype model has been built and tested under various operating conditions, and the obtained experimental results are presented.

Keywords:

• line frequency AC-DC converter
• high frequency transformer
• resonant tanks
• zero voltage switching
• isolated DC-DC converters
• multi-phase DC-DC converter
• interleaved control techniques
• phase shifted pulse width modulation control

Additional information

Notes on contributors

Rakesh Maurya

Rakesh Maurya received B.Tech in Electrical Engineering from the Kamla Nehru Institute of Technology Sultanpur, Uttar Pradesh in 1998 and M. Tech in Electrical Engineering with specialization in Power apparatus and Electric drives from Indian Institute of Technology Roorkee, India in 2002. He is presently pursuing Ph.D. in Electrical Engineering from Indian Institute of Technology Roorkee, India. He is a faculty member in the department of Electrical Engineering, Sardar Vallabhbhai National Institute of Technology Surat, Gujarat, India. His fields of interest include Switching Power Converters, High power factor AC/DC Converters, Power quality problems, Electric drives and applications of Real Time Simulator for the control of power converters.

Satya Prakash Srivastava

Satya Prakash Srivastava received B.Tech and M. Tech in Electrical Technology from I.T. Banarus Hindu University, Varanasi, India in 1976, 1979 respectively and Ph.D in Electrical Engineering from the University of Roorkee, India in 1993. He is currently Professor in the department of Electrical Engineering, Indian Institute of Technology Roorkee, India. His research interests include Electric Machines, Drives, Power Electronics, and Energy Efficient Machines.

Pramod Agarwal

Pramod Agarwal received B. Tech, M.Tech and Ph.D in Electrical Engineering from University of Roorkee in 1983, 1985 and 1995 respectively. He is currently Professor & Head in the department of Electrical Engineering, Indian Institute of Technology Roorkee, India. His fields of interest include Electrical Machines, Power Electronics, Power quality, Microprocessors and microprocessor-controlled Drives, Active power filters, High power factor Converters, Multilevel Converters, and application of dSPACE for the control of Power Converters.