PCD Group 02 Full Bridge Converter Design Report

Pakistan Institute of Engineering & Applied

Sciences
Power Converter Design
Submitted to:

Dr. Tanveer Abbas

Submitted by:

GROUP 02
MUHAMMAD SARWAR
QUDRAT ULLAH

EL-15
EL-19

1ST SEMESTER
MS ELECTRICAL ENGINEERING
2014-2016

DEPT. OF ELECTRICAL ENGINEERING

PIEAS, ISLAMABAD

Full Bridge
Converter
Design

PCD Assignment Full Bridge Converter Design

By: Group-02 | MSEE 14-16

Design Problem:
A 220V utility inverter is to be designed for a load of 1kW. The proposed
block diagram is as under.

12V DC
battery
source

Full
Bridge
Convert

Transfor
mer
(output

Rectifie
r with
LC filter

Full
Bridge
Inverter

Load

Design the highlighted blocks for the above system to meet the
following requirements in addition to above mentioned specifications.
1) The operation frequency of full bridge converter is f=(20+3your
group number) kHz,
2) The filter inductor must remain in continuous conduction mode for
loads 100W or above,
3) Voltage ripple after LC filtering must be less than 5% at full load.
You are expected to provide the following details.
1) Selection of commercially available suitable core for transformer
and inductor (search on internet).
2) Selection of winding conductors considering required current
ratings and skin effect.
3) Number of turns for both transformer and inductor and air gap for
inductor.
4) Expected power loss in transformer and inductor.
5) Expected cost of core material and winding wire.
6) All the datasheet with highlighted parameters of interest that were
considered in the design.
Please state all the valid assumptions you consider, present calculations
and design choices with your preferences.

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PCD Assignment Full Bridge Converter Design

By: Group-02 | MSEE 14-16

he full bridge converter block diagram. The required LC filter

for the rectifier and high frequency transformer will be
designed in this report as per requirement.
An inverter is here

Design Parameters:
Frequency = f = 20 + (3*2) = 26 kHz
Input DC Voltage =Vdc = 12 V
Transformer peak output voltage = Vm = 400 V
Vrms(load) = 220 V,

Pmax = 1000 W,

Pmin = 100 W

Max load current = Irms(max) = Pmax/Vrms = 1000/220 = 4.545 A

Min load current = Irms(min) = Pin/Vrms = 100/220 = 0.4545 A
Consider, the output of full bridge converter that is applied at T/F
primary as given:
Dead band

+12V

-12V
Time period = T = 1/f = 1/26000 = 38.46 uS
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PCD Assignment Full Bridge Converter Design

By: Group-02 | MSEE 14-16

Considering a dead-time of 10%, the Ton can be calculated as

Ton = 0.9*T/2 = 0.9*38.46/2 = 17.31 uS
Neglecting the decaying characteristics and Taking average voltage of
400 and 360 weve
Vpk = (400+360)/2 = 380 V
T/2

Vdc=

1
380 dt=342V
(T /2) 0

T = 10% of T/2 = (0.1*38.46)/2 = 1.923 uS

1
Vrms=
(T /2)

0.9T /2

(380)2 dt= 38020.9=360 V

Voltage & Current waveforms at LC filter

As shown in above figure, an inductor must remain in continuous mode

for minimum load, so average current through inductor is I min = 0.544 A
is considered. From above waveform:
I = 0.91 A
Now,

V = L I/t

>>

L = Vdc * t/I

= 342 * 1.923* 10-6/0.91 = 723 uH =

0.723 mH
RL = V2/Pmax = 2202/1000 = 48.4 V
As the load impedance should be much larger than the capacitor
impedance in an LC filter so we take load impedance to be 10 times
larger than capacitive impedance so,
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PCD Assignment Full Bridge Converter Design

By: Group-02 | MSEE 14-16

RL = 10/(n*2*pi*f*C)
C = 10/(n*2*pi*f*RL)=10/(2*2*pi*26000*48.4) =0.632
uF

Diode and Transformer Secondary Ratings:

P.I.V = Vm = 400 V
As
17.1 V

Ripple Factor = R.F = 0.05 = Vac/Vdc

Vac = 0.05*342 =

Vac

Given that Vripple=0.05= 2 2 So

Vrip(p-p) = 48 V

Vrip = 48/2 = 24 V

Irip = Vrip/R = 24/48.4 = 0.5 V

Irms = 4.545 A
Ipk = 4.545 + 0.5 = 5.04 A
Iavg = 2.25 A,

Irms(D) = 3.504 A, Isec = 4.545 A

Inductor Design:
Inductor Energy storage Equation:
LIpkIrms = kcu Jrms Bm Aw Ac
For copper conductor, the normal value of current density (J rms) within
safety margin is 3.1 A/mm2. As frequency is fairly high so from
performance factor graph, it is evident that 3C85 and 3F3 are the
suitable materials for core. As 3F3 is common ferrite core and its data is
normally easily available so we select 3F3 as core material. So B m for
3F3 can be taken as 0.2 T. For round conductrs and hand would the
copper fill factor, kcu can be 0.4.

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PCD Assignment Full Bridge Converter Design

By: Group-02 | MSEE 14-16

Performance Factor vs. frequency graph of different core materials

So, now the energy storage is

L Ipk Irms = 0.723*10-3*5.04*4.545 = 0.01656 HA2
So,

0.01656 = 0.4*3.1*0.2*Aw*Ac

Weve

Area Product = Aw.Ac = 6.68 cm4

From a table of near optimum core dimensions and size, weve:

Aw.Ac = 2.1 a4 = 6.68 cm4, so a = 1.34 cm
Ac = 1.5 a2 = 2.69 cm2

and Aw = 1.4 a2 = 2.52 cm2

Area of Copper = Acu = Irms/Jrms = 4.545/3.1 = 1.466 mm2 =

0.01466 cm2
Number of Turns = N = Kcu.Aw/Acu = 69 Turns
Maximum Inductance = Lmax = N/I = N.Bm.Ac/I
= (69*0.2*2.52*10-4)/5.04 = 0.734 mH

Air Gap Calculation:

By putting values:
So

Total air gap = 2.19 mm, as No. of air gaps = 2

Air Gap Length = 1.09 mm

Inductor Loss calculation and Cost estimation:

Core Loss:

Psp,core = 1.5*10-6*f1.3*Bac2.5
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PCD Assignment Full Bridge Converter Design

By: Group-02 | MSEE 14-16

= 1.5*10-6*(26)1.3*(0.2)2.5 = 59 mW/cm3
Core Volume:

Vcore = 13.5 a3 = 32.48 cm3

So, Core loss:

Pcore = Psp . Vcore = 59*32.48 = 1.92 Watt

Specific Winding loss: Pw,sp = 22.kcu.(Jrms)2 = 84.568 mW/cm3

Winding volume:

Vw = 12.3 a3 = 30 cm3

So, Winding Loss:

Pw = Vw*Psp,w = 2.54 Watt

Total Core Loss: Ptotal = Pw + Pcore = 4.46 Watt

Copper cost = 1600 Rs./kg,
g/cm3,

Copper

Density

8.96

And Winding Volume = 30 cm3

So, volume of copper = 111.5 cm 3 and Per unit volume Copper cost =
14.4 Rs/cm3
Total Cost of Copper = 172 Rs.
The selected 3F3 core has a cost of 3.1$ i.e 310 Rs.

Transformer Design:
Transformer VA rating equation:
Vrms.Irms = 2.22 kcu Jrms Bm f Aw Ac
For copper conductor, the normal value of current density (J rms) within
safety margin is 3.1 A/mm2. As frequency is fairly high so from
performance factor graph, it is evident that 3C85 and 3F3 are the
suitable materials for core. As 3F3 is common ferrite core and its data is
normally easily available so we select 3F3 as core material. So B m for
3F3 can be taken as 0.2 T. For round conductors and hand wound
winding the copper fill factor, kcu can be 0.4.
The VA rating of T/F is:
Vrms. Irms = 360*4.54 = 1.634 kVA
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PCD Assignment Full Bridge Converter Design

By: Group-02 | MSEE 14-16

As

kcu=0.4, Bm=0.2, f=26 kHz, Jrms=3.1 A/mm2

So,

1634 = 2.22*0.4*3.1*0.2*26000*Aw*Ac

And Weve

Area Product = Aw.Ac = 11.42 cm4

From a table of near optimum core dimensions and size, weve:

Aw.Ac = 2.1 a4 = 11.42 cm4, so a = 1.53 cm
Ac = 1.5 a2 = 3.51 cm2 and Aw = 1.4 a2 = 3.28 cm2
Area of Copper = Acu(sec) = Irms/Jrms = 4.545/3.1 = 1.466 mm2 =
0.01466 cm2
Now,

Vs*Ton = Ns.Bm.Acore

So,

400*17.31*10-6 = Ns*0.2*3.28*10-4

It gives,

No. of secondary turns = Ns = 106 turns

No. of primary turns

As, Is = 4.54 A, so
Also,
mm2

= Np = 106*12/400 = 4 turns

Acu(sec) = Irms/Jrms = 4.54/3.1 = 1.46 mm2

Ip = 4.54*400/12 = 151 A, so Acu(pri) = Ip/Jrms = 151/3.1 = 49

Transformer Loss calculation and Cost estimation:

Core Loss:
59 mW/cm3

Psp,core =1.5*10-6*f1.3*Bac2.5 = 1.5*10-6*(26)1.3*(0.2)2.5

Core Volume:

Vcore = 13.5 a3 = 48.35 cm3

So, Core loss

Pcore = Psp . Vcore = 59*48.35 = 2.85 Watt

Specific Winding loss:

Pw,sp = 22.kcu.(Jrms)2 = 84.568 mW/cm3

Winding volume:

Vw = 12.3 a3 = 44 cm3

So, Winding Loss:

Pw = Vw*Psp,w = 3.75 Watt

Total Core Loss:

Ptotal = Pw + Pcore = 5.59 Watt

Copper cost = 1600 Rs./kg, Copper Density = 8.96 g/cm 3 , Winding

Volume = 30 cm3

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PCD Assignment Full Bridge Converter Design

By: Group-02 | MSEE 14-16

So, volume of copper = 111.5 cm 3 and Per unit volume Copper cost =
14.4 Rs/cm3
Total Cost of Copper = per unit cost*kcu*Vw = 14.4*0.4*44 = 255
Rs.
The selected 3F3 core has a cost of 4.1$ i.e 410 Rs.

Executive Summary:
1. The commercially available cores were searched and the most suitable
cores

for

our

calculated

values

of

Inductor

core

dimension

is

0P45224EC model by Magnetics Ltd. It has centre core leg width and
other dimensions very much close to required value.
2. Similarly, for transformer core the model 0F44721EC best suits the
calculated value. This is a EE type core with all the parameters as per
required.
3. Conductors

cross-sectional

areas

are

calculated

for

inductor,

transformer primary and secondary winding and can easily be acquired

for any electric store selling standard wire gauges or American wire
gauges (SWG or AWG). Though round conductors have been considered,
but for skin effect considerations Litz wire may be used for winding.
4. Number of turns for transformer primary, secondary and inductor
winding have been calculated for the given designed value and
parameters.
5. Power losses (core + winding) for both inductor and transformer have
been calculated.
6. Cost for Cu has been calculated by using per unit cost of Cu conductor.
And for ferrite cores, the cost provided of online dealers has been
considered of a completely manufactured core.
7. Data sheets are attached in here.
8. A MATLAB program has been developed for all the calculations of LC
filter, inductor & transformer design to automate the process and avoid
human errors. This program can be used iteratively to re-design any
value inductor, transformer or LC filter (but only according to the
procedure used here). Similar program can be devolved using MS Excel.

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