Hello, I am designing a boost converter 60-72 volts to 150-200 volts. It will deliver 4 to 10 kw of power. Powered from 5 to 6 lead acid battery.
Current status and chosen topology. Control algorithm - boundary condition mode, two channel interleaved. Controller IC - ucc28061. Switching frequency - minimum 10 khz. Power transistors - irg4pc40fd x 4 with loss less snubbers. Inductor - coupled inductor for dual channel, based on 4xE65 cores from 3c90. Output diode - 150EBU04 x 2.
Possible questions and answers.
10 khz was chosen to use relatively slow igbt but with low voltade drop. Here is simulation results with irg4pc40 igb familiy in S, F, U speed grades, for single and dual igbt. Loss in watts.
70u ~10 khz @40A
Speed - S
27 watt x1
13 watt x2
Speed - F
22.4 watt x1
9.5 watt x2
Speed - U
57 watt x1
17 watt x2
40u ~26 khz @40A
Speed - S
35 watt x1
20 watt x2
Speed - F
23 watt x1
10 watt x2
Speed - U
59 watt x1
18 watt x2
The winner is F series.
Coupled inductor with reduced core loss:
http://repository.lib.polyu.edu.hk/jspui/bitstream/10397/3107/2/b17620296_ir.pdf
Last but not least regenerative loss less snubber -
What left to do in design side - coupled inductor calculation, input output/output capacitor selection, current sensing method, additional driver or not for igbt. Ucc28061 will source to 1 amp, sink to 1.4 amp. + i will left discharge transistor as per snubber diagram.
Any comments are welcome.
Current status and chosen topology. Control algorithm - boundary condition mode, two channel interleaved. Controller IC - ucc28061. Switching frequency - minimum 10 khz. Power transistors - irg4pc40fd x 4 with loss less snubbers. Inductor - coupled inductor for dual channel, based on 4xE65 cores from 3c90. Output diode - 150EBU04 x 2.
Possible questions and answers.
10 khz was chosen to use relatively slow igbt but with low voltade drop. Here is simulation results with irg4pc40 igb familiy in S, F, U speed grades, for single and dual igbt. Loss in watts.
70u ~10 khz @40A
Speed - S
27 watt x1
13 watt x2
Speed - F
22.4 watt x1
9.5 watt x2
Speed - U
57 watt x1
17 watt x2
40u ~26 khz @40A
Speed - S
35 watt x1
20 watt x2
Speed - F
23 watt x1
10 watt x2
Speed - U
59 watt x1
18 watt x2
The winner is F series.
Coupled inductor with reduced core loss:
http://repository.lib.polyu.edu.hk/jspui/bitstream/10397/3107/2/b17620296_ir.pdf
Last but not least regenerative loss less snubber -
What left to do in design side - coupled inductor calculation, input output/output capacitor selection, current sensing method, additional driver or not for igbt. Ucc28061 will source to 1 amp, sink to 1.4 amp. + i will left discharge transistor as per snubber diagram.
Any comments are welcome.