Learning about Magnetics

Learning parts

• designing power magnetics
• samples manufacturing and tesing
• projects’ procedure

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Desinging Power Magnetics

Inductive Components for CMC_2017

What is?

CMC is an filtering element used to reduce the electric noise that can appear in a line in common mode.

When two inductors are used, the distortion of the waveform is large.

When a common mode choke coil is used, the distortion of the waveform is samll.

Magnetic Noise

[What Is Electrical Noise and Where Does It Come From?]

What is Noise?

Noise is a generic word that refers to variations in voltage or current that are oftbe random, usually of relatively loow amplitude, and always undesirable.

Thermal Noise, AKA Johnson Noise

This is a fundamental really associated with resistence to the flow of electrons. Unless we design circuits with superconductors, we’ll always have thermal noise, because everything has at least a little bit of resistance.

Shot Noise

Electrons don’t actually ‘flow’ through a conductor. They with potential energy accumulating and then being converted into kinetic energy each time they cross the barrier.

These random variations in electron motion lead to corresponding random variations in current. In other words, noise.

Shot noise is more prominent in semiconductors because semiconductors have more barriers. Higher current leads to more shot noise.

1/f Noise, AKA Flicker Noise

Flicker noise is generated by most electronic components and decreases in amplitude as frequency increases. As with shot noise, higher current leads to more flicker noise.

Burst Noise, AKA Popcorn Noise

This type of noise occurs only in semiconductors. Imperfections in the semiconductor material lead to abrupt voltage or current transitions. The rapid transitions contain high-frequency energy, but the frequency of the pulses resulting from these transitions is actually rather low.

Differential Mode Current

Differential Mode Vs. Common Mode Conducted Emissions

Every time you connect your device to a power supply, there are two types of currents conducted through the power cable: differential mode currents and common mode currents.

Differential Mode Currents are those normally generated by the device in order to power the device. THey can be also referred to as the supply currents, which generally speaking can be composed of low frequencies(i.e. 50/60 Hz) and high frequencies(i.e. 100kHz).

Common Mode Cureents are usually neglected due only to the parasitic parameters of the whole system, not only to the ones of the device itself.

Winding Types

• Features : Bigger Lk inductance (Lk around 0.5% to 2% of nominal L)
• Applications :
  • Network filters
  • Output filters for SPMS
  • CMC for eletrical network

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Power Topologies Handbook

Genereal Equations for Calculating RMS and AC Currents

Positive Triangular waveforms without offset

![PTWWO2][P2]

Average:

$$avg=\frac{1}{T_{switch}}{\int }_0^{T_{switch}}i(t)\cdot dt$$

$$avg=\frac{max}{2}\cdot \frac{t_1+t_2}{T_{switch}}$$

RMS:

$$rms=\sqrt{\frac{1}{T_{switch}}{\int }_0^{T_{switch}}(i(t){)}^2\cdot dt}$$

$$rms=max\cdot \sqrt{\frac{t_1+t_2}{3\cdot T_{switch}}}$$

AC:

$$ac=\sqrt{rm{s}^2-av{g}^2}$$

Positive trangluar waveforms with offset

![PTWO1][P3]

![PTWO2][P4]

Average:

$$avg=\frac{1}{switch}{\int }_0^{T_{switch}}i(t)\cdot dt$$

$$avg=\frac{min+max}{2}\cdot \frac{t_1+t_2}{T_{switch}}$$

RMS:

$$rms=\sqrt{\frac{1}{T_{switch}}{\int }_0^{T_{switch}}(i(t){)}^2\cdot dt}$$

$$rms=\sqrt{\frac{t_1+t_2}{T_{switch}}\cdot (min\cdot max+\frac{(min-max{)}^2}{3})}$$

AC:

$$ac=\sqrt{rm{s}^2-av{g}^2}$$

About Inductors and Transformers

Coupling between coupled inductors and for transformer windings is assumed to be ideal. The equations for SEPIC, Cuk and Zeta converters are for uncoupled inductors; When calcutating with coupled inductors for those topologies use double the value of the components’ inductance. This also means that for the same ripple requirement a coupled inductor with half the inductance of a single inductor solution is sufficient. Another benefit is that the resonant frequency between inductors and coupling capacitors does not have an effect on the power supplu’s frequency response, but does with single inductors.

About Diodes

The forward voltage drop of rectifier and freewheeling diodes is taken into account for all calculations. It is assumed that the forward voltage drop is identical for those. The forward voltage drop tor demagenetization diodes is neglected for all equations.

About How Waveforms are being displayed

The voltage and current waveforms of components are displayed in thedirection the current is flowing through them. Exceptions are the secondaries of transformers and coupled inductors, because they are considered to be the current sourses.

About RHPZ(Rigth Half Plane Zero)

RHPZ equations for Boost, Inverting Buck-Boost, Cuk, SEPIC, Flyback and Two Switch Flyback topologies are very simplified and thus give the designer only an estimation of the frequency. And for SEPIC and Cuk converters that have more than one RHPZs and only one of them can be calculated to a certain extent.

Buck Converter

A Buck converter steps down an input voltage to a lower output voltage level.

Boost Converter

A Boost converter steps up an input voltage to a higher output boltage level. The energy is transferred to the output when the FET is not conducting.

Inverting Buck-Boost Converter

An inverting Buck-Boost regulator converts a positive input voltage to a higher or lower negtive output boltage level. The energy is transferred to the output when the FET is not conducting.

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[运算放大电路基础]

理想的运放电路两大重要原则：

• “虚短”： 即正端与负端接近短路，$V_{+}=V_{-}$
• “虚断”： 即流入正端及负端的电流接近零，$I_{+}=I_{-}$

运放的典型应用

反相比例放大电路

如图所示，可得到：

$V_{out}=-\frac{R_2}{R_1}\times V_{in}$

推导：

• 电流的流入等于流出，故$I_1=I_2+I_3$，由“虚断”得知，$I_3=0$，故$I_1=I_2$，进而有

$-V=\frac{R_2}{R_1+R_2}\times V_{in}+\frac{R_1}{R_1+R_2}\times V_{out}$

• 又根据“虚短”法则，所以$V_{+}=V_{-}$。又因为运放电路的正端$V_{+}$被$R_3$下拉至地平面，所以$V_{-}=V_{+}=0$。故而

$-V=\frac{R_2}{R_1+R_2}\times V_{in}+\frac{R_1}{R_1+R_2}\times V_{out}=0$

即，

$V_{in}=-\frac{R_2}{R_1}\times V_{out}$

差分放大电路

上图为差分放大电路，是反比例放大电路的“变种”，类似于反向比例放大电路的分析方法，可得：

$V_{out}=\frac{R_1+R_2}{R_3+R_4}\times \frac{R_4}{R_1}\times V_2-\frac{R_2}{R_1}\times V_1$

当$R_1=R_3$且$R_2=R_4$时，得：

$V_{out}=\frac{R_2}{R_1}\times (V_2-V_1)$

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Samples Manufacturing and testing

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Projects’ Procedure

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Extra Learning

[A Comprehensive Review of Power Converter Topologies and Control Methods for Electric Vehicle Fast Charging Apllications]

State-of-the-Art EV Charging

Types:

• on-board Charging
  • Level-1 Charging
  • Level-2 Charging
• off-board Charging
  • Level-3 Charging
  • DC Ultra-Fast Charging(Next Generation)

Charging Station Type	Charger Location	Power Supply	Charger Power Level	Charging Time
Level-1(AC)	On-board(residential charger)	120/230Vac;12A to 16A(Single Phase)	From 1.44kW to 1.92kW	11-36 hours for EVs(16-50kWh)
Level-2(AC)	On-board(charging at home or workplace)	208/240Vac;15A to 80A(Single/split phase)	From 3.1kW to 19.2kW	2-6 hours for EVs(16-30kWh)
Level-3(DC Fast)	Off-board(Charging at pulic similar to gas stations)	300-600Vdc(Maximum current 400A)(Three Phase)	From 55kW to 350kW	Less than 30 minutes for EVs(20-50kWh)
Next Generation: DC Ultra-Fast Charging	Off-board(Charging at pulic similar to gas stations)	800Vdc and higher; 400A and higher(polyphase)	400kW and higher	Approximately 10 minutes for EVs(20-50kWh)

Topologies for AC-DC conversion stage

Three-Phase Buck Type Rectifier

Three-phase buck type rectifier(TPBR) can achieve power factor correction(PFC), low THD, high efficiency, and high-power density, which are the prerequisites for an ac-dc rectifier in the EV charging station. Moreover, TPBR provides inherent inrush current free startup, wider output voltage control range, phase leg shoot through protection, and overcurrent protection circuit during short circuit in comparison with boost type three-phase rectifier. Besides, input current can be controlled without closed-up configurations.

Conventionally, six switch TPBR consists of three legs and one freewheeling diode.

Swiss Rectifier

Swiss Rectifier(SR) is another type of TPBR with eight switches. It has higher efficiency, lower common-mode noise, lower conduction, and switching loss of the switches compared to six-switch TPBR.

Space vector pulse width modulation(SVPWM) can be avoided for SR and hence, control becomes simple.

Full-bridge SR has been demonstrated that considers electrical isolation and ZVS switching intended for improving reliability and efficiency significantly with improved grid power quality.

One key demerit of SR is that it allows only unidirectional power flow.

Vienna Rectifier

The three-phase Vienna refectier(VR) exhibits similarity in operation if compared with a three-phase boost PFC rectifier; however, the power low is unidirectional. Though it retains the benefits of three-level converters, common drawbacks of three-level converters including the requirement of dc-link capacitors are also shared by VR.

VR is widely used in high power applications because of its simple control method, high power density, high power efficiency, reduced number of switches, unity power factor, very low THD(Total Harmonic Current Distortion) and neutral connection-free structure.

The modulation methods for three-phased VR are categorized as carrier-based PWM, SVPWM and discontinuous PWM.

Three-Phase Boost Type Rectifier

Three-phase boost rectifier is well-suited for the ac-dc power stage of the EV charger due to its simplified structure, continuous input current, bidirectional operation, high output dc voltage, low current stress, less number of switches, simple control scheme, low THD, and high efficiency.

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(to be continued…)

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Appendix