The parasitic inductance causes a surge voltage during the turn-off period of semiconductor switches. The effect is serious in a magnet power supply for which a large excitation current is required. With newly developed circuitry and layout of an NPC inverter, cancelation of the induced magnetic field has been accomplished.
The parasitic inductance causes a surge voltage during the turn-off period of semiconductor switches. The effect is serious in a magnet power supply for which a large excitation current is required. With newly developed circuitry and layout of an NPC inverter, cancelation of the induced magnetic field has been accomplished.
The parasitic inductance causes a surge voltage during the turn-off period of semiconductor switches. The effect is serious in a magnet power supply for which a large excitation current is required. With newly developed circuitry and layout of an NPC inverter, cancelation of the induced magnetic field has been accomplished.
Snubber-less NPC inverter by a novel reduction technique of parasitic
inductance for magnet power supplies
K. Koseki n , Y. Morita High Energy Accelerator Research Organization (KEK), 1-1 Oho, Ibaraki, Tsukuba 305-0801, Japan a r t i c l e i n f o Article history: Received 28 February 2014 Received in revised form 21 April 2014 Accepted 23 May 2014 Available online 2 June 2014 Keywords: Magnet Power supply Parasitic inductance Surge voltage NPC inverter a b s t r a c t The effects induced by parasitic inductance were studied in a neutral point clamped (NPC) inverter. The energy stored in the parasitic inductance by the output current causes a surge voltage during the turn- off period of semiconductor switches. The effect is serious in a magnet power supply for which a large excitation current is required. It is predicted by a circuit analysis that the parasitic inductance causes an electrical breakdown of the semiconductor switches. It was found that the most promising way to mitigate the effect is to reduce the parasitic inductance. With newly developed circuitry and layout of an NPC inverter, cancelation of the induced magnetic eld, which is based on Ampere's circuital law, in power devices has been accomplished. The newly developed NPC inverter has been operated success- fully with both a resistive dummy load and the dipole magnets in the main ring synchrotron at the J-PARC facility. & 2014 Elsevier B.V. All rights reserved. 1. Introduction The T2K experiment [1] aims to search for CP violation in the lepton sector following the precision measurement of the last unknown mixing angle, 13 , in neutrino oscillations [2]. For this purpose, we investigated a beam-power upgrade for future multi- MW operation at the main ring of J-PARC [3] by reducing the accelerator's operational cycle from the current value of about 2.5 1 s. Therefore, a new magnet power supply with a shorter repetition cycle needs to be developed. To enable the stable acceleration of MW-class beams and to deliver protons not only to the neutrino facility by fast extraction [4,5] but also to the hadron facility by slow extraction, the new magnet power supply should generate an excitation current with a ripple of less than 2 ppm. Recently, a new operational method that uses a neutral point clamped (NPC) inverter to reject the disturbing effect of common-mode noise was proposed [6]. It also has been reported that by using an NPC inverter with reduced switching sequences, a magnet power supply with sub-ppm ripple performance can be obtained. In a conventional inverter circuit, 4 identical insulated gate bipolar transistors (IGBT) are used to form a full-bridge circuit. By proper gate signals, the conventional inverter can generate 3 out- put voltages: Vc, 0 V and Vc. Here, Vc is the charging voltage of the capacitor bank. In contrast in an NPC inverter, it is possible to generate 5 output voltages (Vc, Vc/2, 0 V, Vc/2 and Vc) by increasing the number of IGBTs for the precise control of the output voltage or the reduction of harmonic components. There- fore, the NPC inverter requires twice as many IGBTs than that of the conventional inverter circuit. Because of the increased number of high-power devices compared to a conventional inverter circuit, an NPC inverter is likely to have a larger parasitic inductance caused by the wiring between each high-power component. A certain amount of magnetic energy is stored in the parasitic inductance by the excitation current. During the turn-off period, the fact that the excitation current in the IGBT is blocked causes a spike voltage, also known as a surge voltage, to be induced in the IGBT. The effect is more serious for a larger current, such as in an accelerator magnet power supply. It is often observed that the surge voltage induces undesired operational performance, such as an increased switching loss or, at worst, an electrical breakdown of the IGBT. Conventionally, a snubber circuit is used to suppress the disturbing effects of the surge voltage in an NPC inverter [7,8]. Although the surge voltage is sufciently reduced by adoption of the snubber circuit, the resulting slow switching time is a disadvantage of this method. To track the beam energy during acceleration, the magnet power supply must generate a pattern current with sufcient precision. For this purpose, a pulse width modulation (PWM) control is utilized, which actively controls the widths of the pulsed output voltages from the inverter. On the one hand, during the period of beam extraction from the synchrotron, relatively wider pulsed voltages are generated for a larger excitation current. On the other hand, a narrow pulse width is required for a smaller excitation current during the period of beam injection into the Contents lists available at ScienceDirect journal homepage: www.elsevier.com/locate/nima Nuclear Instruments and Methods in Physics Research A http://dx.doi.org/10.1016/j.nima.2014.05.095 0168-9002/& 2014 Elsevier B.V. All rights reserved. n Corresponding author. Tel.: 81 29 864 5200 4698. E-mail address: kunio.koseki@kek.jp (K. Koseki). Nuclear Instruments and Methods in Physics Research A 761 (2014) 8691 synchrotron. Moreover, to effectively reduce the ripple compo- nents in the excitation current by the lter circuit, a higher switching frequency of the NPC inverter is required in the new magnet power supply for J-PARC. For example, a charging voltage of 1.6 kV for the NPC inverter of a QFP focusing magnet is required for future 1 Hz operation. To generate an output voltage of 11.2 V during the beam-injection period, which corresponds to a duty factor of 0.7% for the NPC inverter, a pulse width as narrow as 1.4 s is required. Therefore, the IGBTs must have a sufciently fast switching speed. The PWM system can dictate the width only by assuming that the inverter generates pulses with an ideal rectan- gular shape. Because of the slow switching speed with a snubber circuit, pulsed output voltages with an ideal rectangular shape are hard to obtain. Therefore, especially during the beam-injection period, precise control of the output voltage is disturbed by adoption of a snubber circuit. Thus, use of a snubber circuit in the inverter circuit is not suitable for the new magnet power supply. Therefore, we developed a new technique to reduce the parasitic inductance in an NPC inverter. Some parameters of the newly developed NPC inverter are summarized in Table 1. In the devel- oped NPC inverter, a high-power IGBT with a sufcient switching time of 300 ns is employed. In this paper, we present our investigation on the effects induced by the parasitic inductance in the NPC inverter by using circuit simulations. Details of the technique to reduce the parasitic inductance are also discussed. Experimental results are reported from high-power operation with a resistive dummy load to conrm the validity of the newly developed technique. Results are also reported from a high-power test operation using 16 bending magnets at the J-PARC facility to conrm the stability of the developed NPC inverter. 2. Current-blocking surge 2.1. Parasitic inductance The circuit schematic of an NPC inverter and its operational sequences are depicted in Fig. 1. IGBTs are represented by S1-1, S1-2, S2-1, S2-2, S3-1, S3-2, S4-1, and S4-2 in the gure. Parasitic induc- tances are indicated by L cp , L cn , and L14. Stored voltages in the two capacitor banks are represented by Vc/2 and Vc/2, respectively. Sequence (a): simultaneously conducting S1-1, S1-2, S4-1 and S4-2, the charged voltage of Vc in the capacitor bank is applied to the output terminals. Correspondingly, an excitation current indicated by the dashed arrow ows to the load. In this operation sequence, a certain amount of magnetic energy is stored in the parasitic inductances. Sequence (b): by turning off S1-1 and S4-2, the excitation current from the capacitor bank is blocked. Therefore, the current loop changes as depicted by the dashed arrow. The NPC inverter in this operational sequence is in the ywheel mode, in which no voltage is induced at the output terminals. At the switching time of this operational sequence, stored magnetic energy in the parasitic inductances, L cp , L cn , and L14, induces surge voltages at each IGBT because of the sudden change of the current. During the switching period from sequence (a) to (b), the excitation current is blocked by 2 IGBTs, S1-1 and S4-2. Corre- spondingly, because of the sudden change in the current, parasitic inductances, L cp , L cn , and L14, induce surge voltages. The ampli- tude of the voltage applied to an IGBT is expressed as V s11
1 2 V c L cp L1 dI dt : 1 Here, I is the current blocked by S1-1. From Eq. (1) it can be seen that in a power supply with a large output current, such as for a synchrotron magnet, the effects induced by the parasitic inductance are strong. By increasing the peak amplitude of the voltage during the switching period, the switching loss in an IGBT is increased. In the worst case, with a surge voltage larger than the rated voltage of the IGBT, an electrical breakdown can occur. To conrm the validity of Eq. (1) and to investigate the nature of the surge voltage, we performed simulation studies based on the circuit schematic in Fig. 1. In the simulation, an output current of 300 A which is supplied from a capacitor voltage of 1400 V to a resistive load of 4.7 is switched by IGBTs in the NPC inverter. The IGBT is modeled by an ideal switch without parasitic elements, such as the output capacitance and turn-on resistance. The CollectorEmitter voltages of S1-1 for various parasitic induc- tances (Lcp, Lcn, L1, L2, L3 and L4) are shown in Fig. 2. The results show a linear dependence of the peak amplitude of the surge voltage on the parasitic inductance. A current depen- dence of the surge voltage is also simulated. The result is shown in Fig. 3. Various load resistances are used to simulate the Emitter current of 400 A (a 0 ), 300 A (b 0 ), 200 A (c 0 ), and 100 A (d 0 ) by a charging voltage of 1400 V to the capacitor bank. CollectorEmitter voltages for the corresponding Emitter currents are indicated by (a), (b), (c), and (d). In Fig. 2, the surge voltage superimposed on the CollectorEmitter voltage is increased linearly with the increase of the parasitic inductance. Moreover, a linear increase of the surge voltage with the increase of the Emitter current is observed in Fig. 3. Therefore, the simulation studies conrm the validity of Eq. (1). To solve the problem induced by the current-blocking surge voltage, a snubber circuit is commonly used. However, it is clear from Eq. (1) that reducing the parasitic inductance is a natural approach. With sufcient reduction, a snubber-less NPC inverter that is capable of a faster switching frequency for lower output ripple in the excitation current is required. 2.2. Reduction method To reduce the parasitic inductance, it is essential to reduce the induced magnetic eld by a current loop that includes two capacitor banks, S1-1, S1-2, and S4-1, S4-2 (see Fig. 1(a)). From Ampere's circuital law Z Hds i n i I i : 2 It is found that the induced magnetic eld is canceled by two currents with opposite directions but the same amplitude. Here, I i is the current, and n i is the number of turns of the ith circuit. H indicates the total induced magnetic eld. To apply the reduc- tion method expressed by Eq. (2), power devices and wiring bus bars with the same current amplitude should be placed side by side. Thus, the reduction of the parasitic inductance is difcult in a conventional NPC inverter because S1-1 and S4-2 are placed in diagonally opposite positions, as shown in Fig. 1. Therefore, new circuitry for an NPC inverter is proposed. The circuit schematic is shown in Fig. 4. In the gure, the current loops in sequences Table 1 Parameters of the developed NPC inverter. Peak output power 300 kVA Maximum charging voltage 1800 V Peak output current 300 A Repetition rate 5 kHz IGBT CM1000DUC-34NF Rise/fall time 300 ns K. Koseki, Y. Morita / Nuclear Instruments and Methods in Physics Research A 761 (2014) 8691 87 (a) and (b) are depicted by solid and dashed arrows, respectively. Although twice as many capacitor banks are used in the new circuit, S1-1 and S4-2 can be easily placed in contiguity with each other. Therefore, cancellation of the induced magnetic elds can be accomplished by two wiring bus bars for S1-1 and S4-2. The structural layout of the new NPC inverter is shown in Fig. 5. The wide-solid arrow indicates the current loop in sequence (a). The ywheel diodes are removed from the gure for simplicity. 3. Evaluation The previous chapter showed that reduction of the parasitic inductance in an NPC inverter is important to secure stable operation. For this purpose, new circuitry and its structural design for an NPC inverter were presented. With this newly proposed innovative technique, an NPC inverter that is capable of high- power operation has been developed as shown in Fig. 6. We conducted a high-power test operation with a resistive dummy load of 4.6 to evaluate the operational performance of the newly developed NPC inverter. Although the synchrotron mag- nets are the large inductive load, the resistive load with compatible impedance seems to be sufcient to evaluate the voltages and currents in the IGBT. An Emitter current of about 300 A, which was supplied from a capacitor voltage of 1400 V, was switched by IGBTs in the newly developed NPC inverter. The results are shown in Fig. 7. Results from simulation with the parasitic inductance of 250 nH are Fig. 1. Circuit schematic of a conventional NPC inverter. Fig. 2. Simulated surge voltages of S1-1 for various parasitic inductances (Lcp, Lcn, L1, L2, L3 and L4) of 400 nH (a), 300 nH (b), 200 nH (c) and 100 nH (d). The charging voltage of the capacitor bank was 1400 V in the simulation. Emitter current of S1-1 is also depicted in (e). Fig. 3. Simulated surge voltages of S1-1 for various emitter currents. The parasitic inductances (Lcp, Lcn, L1, L2, L3 and L4) were 300 nH in the simulation. Fig. 4. Schematic of the proposed circuitry of an NPC inverter. Solid and dashed arrows indicate the current loop in sequences (a) and (b), respectively. K. Koseki, Y. Morita / Nuclear Instruments and Methods in Physics Research A 761 (2014) 8691 88 also depicted in Fig. 8 for a comparison between the measurement and the simulation. From the peak value of the CollectorEmitter voltage of about 900 V (line (a) in Fig. 7), which is less than the absolute maximum rated voltage of 1700 V for the IGBT, stable operation is conrmed. The switching time was also measured by the Emitter current (b) to be about 280 ns, which is consistent with the specication of 300 ns in the data sheet. By a comparison between the measured (line (a) in Fig. 7) and simulated (line (a) in Fig. 8) Collector Emitter voltage, fairly good agreement is also conrmed. There- fore, each of the parasitic inductances (Lcp, Lcn, L1, L2, L3 and L4 in Fig. 1) is estimated to be about 250 nH. It was difcult to secure a stable operation without snubber circuits in a conventional NPC inverter with the existing technology. The newly developed NPC inverter demonstrated the snubber-less operation by a sufcient reduction of the parasitic inductance with the proposed method. Fig. 5. Structural drawing of the proposed NPC inverter. Solid arrow indicates the current loop in sequence (a). Fig. 6. Photograph of the developed NPC inverter with reduced parasitic inductance. Fig. 7. (a) Measured CollectorEmitter voltage and (b) Emitter current of S1-1 during high-power test operation with a dummy load. Fig. 8. (a) Simulated CollectorEmitter voltage and (b) Emitter current of S1-1 with the parasitic inductance of 250 nH. K. Koseki, Y. Morita / Nuclear Instruments and Methods in Physics Research A 761 (2014) 8691 89 The temporal evolution of the power dissipation in the IGBT during the turn-off period was also calculated by multiplying the measured CollectorEmitter voltage and Emitter current (Fig. 9). By integrating the result over time and multiplying by the switch- ing frequency of 4 kHz, the switching loss during the turn-off period is estimated to be about 200 W. From the thermal resis- tance of about 20 K/kW of an indirect-water cooling system and of the IGBT itself, the estimated temperature increase in the IGBT is about 4 K. Stable operation is also conrmed from the viewpoint of the temperature increase. 4. High-power operation at J-PARC To conrm stable operational performance, the developed NPC inverter was installed into a prototype magnet power supply. The circuit schematic of the magnet power supply is depicted in Fig. 10. The prototype magnet power supply consists of a 3-phase input transformer with an output power of 300 kVA, a full-bridge diode rectier, a 90 mF aluminum electrolytic capacitor bank, the developed NPC inverter, and a lter circuit. Parameters of the prototype magnet power supply are summarized in Table 2. High- power operation with 16 bending magnets, each having an inductance of 100 mH and a coil resistance of 40 m, was conducted in the main ring synchrotron at the J-PARC facility with a peak excitation current of 100 A. The charging voltage for the capacitor bank was 1800 V in this operation. The measured excitation current and the output voltage are shown in Fig. 11 (a) and (b), respectively. From these results, stable operation of the magnet power supply and thus the newly developed NPC inverter has been conrmed. 5. Conclusion To secure stable acceleration during future MW-class beam operations at J-PARC, a new magnet power supply with current ripple of less 2 ppm is required. For this purpose, we proposed a new operational method of an NPC inverter for the rejection of common-mode noise. The NPC inverter is likely to have a larger parasitic inductance caused by the wiring than would a conven- tional inverter because of the number of power devices. The surge voltage induced by the parasitic inductance causes serious effects on the operation of the NPC inverter, such as increased switching loss or, at worst, electrical breakdown of the power devices. Fig. 9. Temporal evolution of the power dissipation in the IGBT (S1-1) during the turn-off period. Fig. 10. Circuit schematic of the prototype magnet power supply with the newly developed NPC inverter. Table 2 Parameters of the prototype magnet power supply with sub-ppm output ripple. Charging voltage 1800 V Maximum current 300 A Repetition rate 1 Hz Filter inductance 1.5 mH Filter resistance 3 Filter capacitance 1.5 mF Switching frequency of NPC inverter 4 kHz Capacitor bank 90 mF Fig. 11. (a) Measured excitation current and (b) output voltage by the newly developed magnet power supply. K. Koseki, Y. Morita / Nuclear Instruments and Methods in Physics Research A 761 (2014) 8691 90 To mitigate the disturbing effects by means of reducing the parasitic inductance, new circuitry and structural layout of an NPC inverter was developed. With a sufcient reduction, an NPC inverter was developed that operated successfully with both a resistive dummy load and the dipole magnets in the main ring synchrotron at the J-PARC facility. It should be mentioned that the newly developed method is applicable not only for the NPC inverter but also for the conventional inverter to reduce the parasitic inductance and to mitigate the disturbing effect by the current-blocking surge voltage. Acknowledgments The authors are grateful for the continued support of Professors H. Kobayashi, M. Yoshioka, and H. Matsumoto. One of the authors (K. Koseki) expresses his gratitude to Dr. Y. Kurimoto, Mr. Kondo and Mr. Kageshima for their valuable cooperation in developing the NPC inverter. References [1] T2K collaboration, Nuclear Instruments and Methods in Physics Research A 659 (2011) 106. [2] T2K Collaboration, Physical Review Letters 112 (2014) 061802. [3] Y. Yamazaki, et al., Accelerator technical design report for J-PARC, 2002-13 (KEK Report) [4] K. Koseki, Nuclear Instruments and Methods in Physics Research A 729 (2014) 3. [5] K. Koseki, H. Matsumoto, Nuclear Instruments and Methods in Physics Research A 739 (2014) 63. [6] K. Koseki, Y. Kurimoto, Nuclear Instruments and Methods in Physics Research A 747 (2014) 24. [7] M.H. Pong, et al., IEE Proceedings B 134 (2) (1987) 69. [8] Z. Lounis, et al., IEEE Transactions on Power Delivery 15 (2) (2000). K. Koseki, Y. Morita / Nuclear Instruments and Methods in Physics Research A 761 (2014) 8691 91
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