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GROUP 02
MUHAMMAD SARWAR
QUDRAT ULLAH
EL-15
EL-19
1ST SEMESTER
MS ELECTRICAL ENGINEERING
2014-2016
Full Bridge
Converter
Design
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.
2 | Page
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
+12V
-12V
Time period = T = 1/f = 1/26000 = 38.46 uS
3 | Page
Vdc=
1
380 dt=342V
(T /2) 0
1
Vrms=
(T /2)
0.9T /2
V = L I/t
>>
L = Vdc * t/I
RL = 10/(n*2*pi*f*C)
C = 10/(n*2*pi*f*RL)=10/(2*2*pi*26000*48.4) =0.632
uF
Vac = 0.05*342 =
Vac
Vrip = 48/2 = 24 V
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.
5 | Page
0.01656 = 0.4*3.1*0.2*Aw*Ac
Weve
Psp,core = 1.5*10-6*f1.3*Bac2.5
6 | Page
= 1.5*10-6*(26)1.3*(0.2)2.5 = 59 mW/cm3
Core Volume:
Vw = 12.3 a3 = 30 cm3
Copper
Density
8.96
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
7 | Page
As
So,
1634 = 2.22*0.4*3.1*0.2*26000*Aw*Ac
And Weve
Vs*Ton = Ns.Bm.Acore
So,
400*17.31*10-6 = Ns*0.2*3.28*10-4
It gives,
As, Is = 4.54 A, so
Also,
mm2
= Np = 106*12/400 = 4 turns
Core Volume:
Winding volume:
Vw = 12.3 a3 = 44 cm3
8 | Page
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,
9 | Page