Old Exam (2001)

1. The four quadrant DC-DC converter

a) As in your project reports!
b) Consider the blanking time circuit used in the laboratory converter
R1 open collector pull-down resistor and R2 potentiometer in parallel with diode

vC = VCC 1 e t

V
t = ln 1 C
VCC

The transfer at the buffer output occurs when VC =V

d) Fundamental component of the AC-side current

VLN,rms = 230 V, 50 Hz assume cos = 1
I1,line =

PLOAD,max
4000 W
=
= 17.4 A (rms, fund. comp.)
230 V
VLN,rms cos

e) Rectifier losses?
In the previous exercise the fundamental of the line side current was calculated.
However, The current is not sinusoidal but contains a large amount of harmonics.
From Figure 1 it is clear that if the fundamental has a peak level of 1 then the real
current has a peak value of 3.15. Therefore, the diode current has a peak value of
iD = 3.15 i1,line = 3.15 2 I1,line = 3.15 2 17.4 A = 77.5 A
The diode current pulses have duration tp=2.75 ms according to the same figure.

From Fig. 2 of the rectifier data sheets the forward characteristics are found to be
iD = 10 A v D = 0.78 V

iD = 100 A vD = 1.39 V

VD 0 = 0.712 V

RD = 6.78 m

The diode losses are calculated from the integral (fn=50 Hz Tn = 20 ms)
T

1 n
1 p
1 p
PD = p(t ) dt = p(t ) dt = VD 0 iD (t ) + RD iD2 (t ) dt =
Tn 0
Tn 0
Tn 0
2

iD
tp
tp
2
2

= VD 0 I avg + RD I rms
= VD 0 iD + RD

Tn

2 Tn
= 4.84 + 2.81 W = 7.65 W
The total rectifier losses are:
Prect = 4 PD = 4 7.65 W = 30.6 W

f)

DC link capacitor
The time derivative of the DC link voltage when no rectifier diode conducts is
found from Figure 1

dv DC
= 9789 V/s
dt
The average current drawn by the converter is given by
I DC,avg = DLOAD I C,max = {DLOAD = 0.95} I C,max = 16 A
For a capacitor
I DC,avg
dvC
iC = C
C DC =
= 1.6 mF
dt
dv DC dt

g) IGBT and freewheeling diode conduction characteristics

From Fig. 2 of the IGBT data sheets the forward characteristics of the IGBT are
found to be

I C = 1.0 A, T j = 150 o C VCE = 0.8 V

o
I C = 10 A, T j = 150 C VCE = 1.35 V

VCE 0 = 0.74 V

RCE = 0.06

VCE = 1.7 V at I C = 16 A, T j = 150 o C

From Fig. 13 of the IGBT data sheets the forward characteristics of the
freewheeling diode are found to be
I D = 1.0 A, T j = 150 o C VD = 0.9 V

o
I D = 10 A, T j = 150 C VD = 1.18 V
VD = 1.35 V at I C = 16 A, T j = 150 o C

VD 0 = 0.87 V

RD = 0.031

h) Switching losses of the IGBTs and freewheeling diodes

Note that the switching losses are calculated for the worst case DC link voltage,
i.e. with VDC = vLN = 325 V when the duty-cycle is close to zero and with the
average DC link voltage (290 V according to Figure 1) when the duty-cycle is
close to one.
IGBTs

From Fig. 10 of the IGBT data sheets the total switching losses of the IGBT are
found to be
ETS = 0.110 21.5mm 20 mm mJ = 1.19 mJ at VDC = 480 V, I C = 20 A, T j = 150 o C
In this application this means that the switching losses (for one IGBT) are
1.19 10 3
Psw = ETS f sw =
VDC I C f sw =
290 16 10 103 W = 5.75 W
VDC ,n I C ,n
480 20
ETS ,n

Freewheeling diodes

From the table Switching Characteristics:

tr=52 ns for IC = 20 A, RG = 10 and Tj = 150 C (for the IGBT)
diF
20
=
A/s = 385 A/s

9
dt 52 10
Fig. 15 gives (Note that log(385/100)=0.585 0.585 37.4 mm = 21.9 mm):
I RRM = 110 26 mm 25.5mm A = 10.46A
Fig. 17 gives (Note that log(385/100)=0.585 0.585 37.4 mm = 21.9 mm):
direc
= 100 10 24.75mm 50.5mm A /s = 309 A/s
dt
direc I RRM
I RRM
=
t rr 2 =
= 33.9 s
dt
t rr 2
direc dt

1
1
QF = I RRM t rr 2 = 10.46 33.9 10 6 C = 177 nC at I F = 15 A
2
2
QF =

16
177 nC = 189 nC at I F = 16 A
15

The turn-off energy loss is thus

E Drr = QF VDC = 189 10 9 290 J = 54.8 J at I F = 16 A

The average switching power losses for one freewheeling diode are given by
Psw = E Drr Fsw = 54.8 10 6 10 103 W = 0.55 W
i)

Conduction losses
DLOAD = 0.95:

Pcond,IGBT=VCEICDIGBT=26.5 W/IGBT
Pcond,FWD=VDIDDD=0.54 W/FWD

DLOAD = 0.05:

Pcond,IGBT=VCEICDIGBT=0.68 W/IGBT
Pcond,FWD=VDIDDD=21.1 W/FWD

j)

Thermal design
DLOAD = 0.95

PIGBT = 32.3 W/IGBT, Rth,jh=0.77+0.24 C/W = 1.01 C/W

PFWD = 1.1 W/FWD, Rth,jh=1.7+0.24 C/W = 1.94 C/W
Prect = 30.6 W/FWD, Rth,jh=1.7+0.2 C/W = 1.9 C/W
Assume Tj = 125 C

Th,max,IGBT = 125-32.31.01 C = 92.4 C

Th,max,FWD = 125-1.1194 C = 122.9 C
Th,max,rect = 125-30.61.9 C = 66.9 C
PTOT = 2PIGBT +2PFWD +Prect = 97.4 W
Ta = 30 C
Rth,ha =

66.9 30 o
C W = 0.379 o C W 0.38 o C W
97.4

2. Snubbers
a) Draw a step down converter

Vdc

b) Draw a step down converter with an RCD

charge-discharge snubber

iC

iC

vCE

vCE Ds

Rs

Vdc +

Iload

Iload

Assume that the transistor current decreases linearly at turn-off (in principle true
for MOSFETs)

0 < t < t fi
iT = I 0 1
t
fi

This gives the snubber capacitor current

iCs

t
t
= I 0 iT = I 0 I 0 1 = I 0 0 < t < t fi
t
t fi
fi

The snubber capacitor voltage is calculated by integration of the capacitor current

vCs

I0 t 2
1 t
=
iCs dt =

CS 0
2 CS t fi

If it is assumed that the blocking voltage increases during tfi

vCs (t fi ) = VDC C S =

I 0 t fi
2 VDC

vCs

t
= VDC
t
fi

c) Stray inductance
vL = L

v
diL
di
70
= L T L = L =
H = 350 nH
9
dt
diT dt 26.1/130 10
dt

d) RCD clamp snubbers

Cs

Rs

Ds

CS

RS

e) Transistor technology?
Tail current IGBT
f)

Alter drive circuit?

Reduce over-voltage decrease the current derivative increase RG

VCC VGE

vGE = VCC + 1 - e
2 VCC t = ln
2 VCC
VCC VGE ,th
VCC VGE ,I 0
VCC VGE ,th
+ ln
= ln
t fi = ln
VCC VGE ,I
2 VCC
2 VCC

0
-t

= const

In the altered case

v L = 56 V v L = 30 V

diT
di
30
= 200 A/s T = 200 A/s = 107 A/s
dt
dt 56

This means that tfi should increase by a factor 200/107=1.87 since I0 is unaltered.
This is accomplished by increasing = RG(Cgs+Cgd). Note that Cgd is
approximately constant since the IGBT voltage is vCE 200 V during the current
fall. Therefore, RG should be increased by a factor 1.87.

3. The flyback converter

a) Draw the main circuit - As in your project reports!
b) Explain the need and operation of the snubbers - As in your project reports!
c) Determine the winding turns ratio and the air gap of the core
v1 = 300 V v2 = 30 V
N1 300

= 10

N 2 30
v2 = 30 V v1 = 300 V
30
di2 3.38 A
v2
H = 3.38 A/ms L2 =
=
=
H = 88.8 H
dt 10 s
di2 dt 3.38 10 -3

N 2 = 10 AL =

L2

N 22

88.8 H
10

= 887 nH 900 nH l = 200 m

d) Sketch the magnetizing current and calculate core losses

,max = 0.54 A, im
,min = 0.22 A, Triangle with f1 = 50 kHz and D 0.5
im

or

i
,min = 2.2 A, Triangle with f1 = 50 kHz and D 0.5
m,max = 5.4 A, im
= Lm
im
= B N1 AFe

2
9
m

L
i
(
)
10

10

900

10
0.54
m
B =
=
T = 281 mT

6
N1 AFe
10 10 173 10

NOT saturated!

= 0.38 +
im

0.1297
2

cos(n 2f1t ) A, f1 = 50 kHz

n
,1 = 0.1297 A peak
The fundamental component of the magnetizing current: im
n=1

= Lm
im
= B N1 AFe

2
9

(
)
L
i
10

10

900

10
0.1297
m m

=
B=
T = 67.5 mT
6
N1 AFe
10 10 173 10

Fig. 6 (67.5 mT and f=50 kHz): Pv=30 kW/m3

VFE=1780010-9 m3 PFe,50kHz=0.534 W