BITS-Pilani, K.

K Birla Goa Campus Semester II 2011-2012 EEE/INSTR C461 Power electronics Design Assignment 20-04-2012
Weightage 15% (MM: 45) General Instructions
Submit the assignment neatly handwritten in A4 size sheets utilizing both sides. Do not exceed more than 3 pages (6 sides) for the written parts. No printed material except for the specified MATLAB exercises. Show the final answers enclosed in a rectangular box. For the control model analysis, design and validation parts, you may print the responses from the MATLAB environment (printed material restricted to 2 pages)

Due on: 24-04-2012 (Tuesday) 5pm.

Part A (20 marks)

A Buck converter is to be designed to operate as a regulator at a nominal input voltage, Vin. In reality the input voltage may vary. The converter is to maintain an output voltage of 10V. The load requirement may vary from 200W to 250W. Other specifications are given as follows. Identify the data corresponding to your ID number from Table 1 in the following manner.
Identify the last two digits of your ID number, say, n. Depending on whether n is a prime number, choose your Vin. Choose the input voltage variation and the switching device (MOSFET) part number, by identifying if the number n is even or odd. Choose the appropriate inductor current ripple specification by checking mod (n, 4). Choose the appropriate output voltage ripple specification by checking mod(n,3) Choose the switching frequency by checking mod (n, 4).

Vin

Input voltage Variation ( percentage of nominal input value) 20V odd even 20% 10%

Maximum allowable Switching Max allowable output Inductor current Switch part no voltage ripple () frequency ripple () STD60N3LH5 STD85N3LH5 mod(n,4)=0 mod(n,4)=1 mod(n,4)=2 5% 10% 20% 5kHz 10kHz 20kHz 50kHz mod(n,3)=0 mod(n,3)=1 mod(n,3)=2 0.10% 0.50% 1.00%

Prime

Non-Prime 40V

mod(n,4)=3 100%

Table 1

1) Find the range of duty ratio for the converter operation. 2) Design the inductor and capacitor values for the given specifications. 3) Refer to the ST micro datasheets for the parts and calculate the ON state conduction losses, OFF state conduction losses and switching losses for the worst case. (Assume linear rise and fall of currents and instantaneous change in the voltages, i.e., rectangular trajectory in the V-I plane for switching.) 4) Assuming a constant drop of 0.7V, compute the ON state losses in the diode. 5) Evaluate the minimum values of the peak ON current and peak blocking voltage ratings for the diode and switch. 6) Find out the extreme operating points and check whether they are well within the Safe Operating Area. (Fig 2 of the datasheet) 7) Determine whether a heat sink is needed for operation of the converter if the junction temperature is to be limited to 2500C. Assume an ambient temperature of 400C and case to sink thermal resistance of 0.5 oC/W. If yes, compute the maximum heat sink thermal resistance. (For STD85N3LH5, take IPAK specifications). You need not do the heat sink design.

Example for identifying your design specifications: 1. Consider the ID number 2009A3PS069G. The number n corresponding to the last 2 digits is 69. 2. The number is not a prime. So choose Vin= 40V from the table. 3. It is an odd number. Choose variation in Vin as 20%. The MOSFET STD60N3LH5 is to be chosen as the switch. 4. Perform modulo-4 operation. That is, mod (69,4) = 1. Choose allowable current ripple as 10%. The switching frequency is chosen as 10 kHz. 5. Perform modulo-3 operation on the number 69. Mod (69,3) = 0. Hence, choose output voltage ripple as 0.1%.

Hints and guidelines for the Buck converter design a) Identify the worst case conditions and design the converter. Ignore the inductor and capacitor non- idealities. b) For on state losses identify the current through the switch and diode. Use the ON state model of the devices to compute the losses.

c) For heat sink calculation, refer example 29-2 of the text book.

Part B (15 marks)

1. Write down the differential equations of the Buck converter in Part A. Consider the non-idealities of the switch, diode, capacitor and inductor. The diode may be modelled as a constant voltage drop V in the ON state and as an ideal switch in the OFF state. Model the MOSFET as a resistance rd in the ON state and as an ideal switch in the OFF state. Assume a winding resistance of rL in series with the inductor and an ESR of rC in series with the capacitor. 2. Obtain the large signal state-space representation of the converter in the ON and OFF state. 3. Obtain the average state-space model of the converter. 4. Obtain the steady state and small signal state-space models of the converter. 5. Find the transfer function of the converter from duty ratio (input) to output voltage. MATLAB exercises 6. Substitute the numerical values obtained from the design exercise in Part A and plot the pole-zero map of the system. Use ESR value rC= 0.01 and series resistance of the inductor rL=0.05 (You may use MATLAB plots.) You may neglect V. 7. Obtain the bode plot of the converter and identify the corner frequency (frequencies). 8. Design a controller such that the peak overshoot in the inductor current is limited to 20% for a step change of 4V in the input from the nominal input value (i.e., if Vin= 20V, the step is from 20 to 24V). A zero steady state error in the output voltage is also required to be implemented. (You may neglect the ripple in the output voltage in this context.) Implement the converter in Simpower system blockset in MATLAB Simulink environment. Connect the controller and close the loop. Validate the controller performance by applying a step change in the input voltage. Plot the input voltage, inductor current, output voltage and input current during the step change transition, with respect to time.
Hints and guidelines for the using Simpower blockset Use powergui block in the model if you are using MATLAB version higher than 7. Set the solver type to variable step and numerical solver to ODE23tb stiff. (Simulation>configuration parameters>solver)

Part C (10marks)
1. Design a single phase capacitor filtered bridge rectifier, which is to be connected as the input DC supply for the given DC/DC converter in Part A. Use a step-down transformer for the reduction in the sinusoidal input. 2. Choose the capacitor value such that the ripple in the output capacitor voltage should be limited to 10%. Assume the output current to be a constant DC current, neglecting the switching frequency harmonics due to the DC/DC converter operation. Obtain the output current specification from the Buck converter input current specification. 3. Find the voltage and current ratings of the diodes used in the rectifier.

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