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2003 Future Energy Challenge “Energy Challenge in the Home”. Matt Pagendarm, Mark Wu Boost PFC, Team 41 4/30/03. 2003 FEC Background. Create a Motor and Drive System Motor System Characteristics: Output power range 50W - 500W (<1HP) Motor Speed ranges from 150RPM - 5000RPM Efficiency > 70%

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2003 future energy challenge energy challenge in the home

2003 Future Energy Challenge“Energy Challenge in the Home”

Matt Pagendarm, Mark Wu

Boost PFC, Team 414/30/03


2003 fec background
2003 FEC Background

  • Create a Motor and Drive System

  • Motor System Characteristics:

    • Output power range 50W - 500W (<1HP)

    • Motor Speed ranges from 150RPM - 5000RPM

    • Efficiency > 70%

    • Power Factor > 0.8

    • Operate from a single phase 120 Vac source

    • Cost less than $40 (per million quantity)



Motivation for pf correction
Motivation for PF Correction

  • Lowers Peak Currents

  • Lowers Total Losses

  • Power Grid Friendly


Why choose boost pfc
Why Choose Boost PFC?

  • Keep It Simple

  • Average Current Mode Control

  • Boost Converters Naturally Drive Current

  • Component Ratings Inverter Drive

  • Cost Effective


Boost pfc system specifications
Boost PFC System Specifications

  • True Specifications

    • Voltage Ripple +/- 10V

    • Input Current Ripple +/- 1 Amp

    • >95% Efficiency

    • Near 1 Power Factor

    • Actual output 80W - 800W

    • Inrush Current < 150% Rated Load (<15 Amps)


System design calculations
System Design & Calculations

  • PWM Boost ~ Backwards Inverter

    • Desired Duty on Diode

    • Duty on Transistor


System design calculations1
System Design & Calculations

  • Inductor

    • Hand wound Ferrite inductor

    • 1.5mH

  • Capacitor

    • Size Driven by Necessary Ripple Current (10A)

    • 3 – 2200uF capacitors (3.5A each)


System design calculations2
System Design & Calculations

  • Fairchild 17N40 Mosfet

    • Cheap - $0.91 (Qty: 1000)

    • 17 Amp conduction, 400V blocking

    • Low Rds(on)

  • MUR1540 Ultrafast Diode

    • 15 Amp conduction, 400V blocking

  • GSIB1540 Vishay Rectifier

    • Cheap - $0.79 (Qty: 1000)

    • 15 Amp conduction, 400V blocking



Feedback control

Voltage Loop

Slow Response

Filter 120Hz Input

Current Loop

Fast Response

Match Current to Vin

Feedback Control


System protection
System Protection

  • Over Voltage on Bus

    • Set to 230 V

    • Verified in Testing

  • Over Current on Input

    • Set to 10 Amps

    • Verified in Testing

  • Open load (Bus disconnected)

    • Discharge of 6.6mF capacitors

    • Verified in Testing

  • Input Fuse

    • Incorporated with IEC320 Package


Build system
Build System

  • Build 42V

    • Convenience

    • Low Voltage

    • Scaled System of 200V

  • Build 200V

    • Learn from 42V

    • Finalize Device Selections


42v boost pfc operation
42V Boost PFC Operation

17 Watts

Rsense – 0.25 Ohm

Classical Rectifier

Power Factor Corrected Rectifier


200v boost pfc operation
200V Boost PFC Operation

Rsense – 0.10 Ohm

Peak Limit Verified

100 W Load

200 W Load


Challenges voltage loop
Challenges - Voltage Loop

Rsense – 0.10 Ohm

Over Voltage Verified

100 W

160 W


Challenges ground loops
Challenges – Ground Loops

200V Layout

42V Layout


Challenges noise r sense
Challenges – Noise & Rsense

  • 42V Rsense 0.25 Ohms

    • Vrsense = 800mV

  • 200V Rsense 0.05 Ohms

    • Minimun load, Vrsense = 50mV

    • Needs filtration

  • Moved to Rsense 0.10 Ohms



Recommendations
Recommendations

  • Utilize DSP’s extra PWM controller

    • Lower cost

    • Smaller layout, size

  • Ultra-low Rsense or transformer current sensing


Upcoming events
Upcoming Events

  • PC Board Layout Submitted

  • Induction Motor Laminations Cut

  • Integration with Inverter & Motor Team

  • Final Competition Event:

    • May 21-24, 2003

    • Raleigh, North Carolina



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