DC-Link Input Exploration Harry Johnson Motivation: General Specs: - PowerPoint PPT Presentation

DC-Link Input Exploration Harry Johnson

Motivation:

General Specs: ● SiC low-side FET ● SiC high-side diode ● 1Mhz Switching Frequency ● Output cap appropriately sized. ● Average input current control loop.

Low-Side FET: Cree C2M0280120D ● 280mR RDSon

High-Side Diode: Cree C4D05120A ● Output current is actually rather low ● Optimize Qrr

MATLAB: ● Simple and quick to run sanity check ● Only models cycle-by-cycle, not control inside cycle ● Results used earlier

LTSpice Overview: ● Models circuit behavior within cycle ● Runs for a single 120Hz cycle ● Exported setpoints from MATLAB to CSV, imported as PWL files for current sources. ● Rest of Littlebox (main buck, DC-link output buck) modeled as current sources where necessary. ● SiC devices: manufacturer-supplied models

LTSpice Schematic: Main Buck Emulator 450V + 10R DC-Link Input DC-Link Current Setpoint Capacitor Package Discharge Inductance Current Total Current setpoint: 5A w/ soft start

Per-120Hz cycle plots.

Turn-On

Turn-Off

Calculated Results: ● Averaged over the entire charge cycle ● Power In: 1.3195KW ● Power Out (into cap): 1.2888 KW ● Switching Power Loss: 30.7 Watts ● Eff: 97.6% (only including switching loss)

Areas for Future Work ● Model capacitor ESR appropriately for mega-cap array (not modelled at all for purposes of this simulation) ● Inductor losses: DCR relatively easy to model but I suspect primary losses will be in core. ● Actually build the darn thing!

Bonus: Megaderp moment Late-night calculations: ● Automatic power calculation in LTspice (alt-click) on Cree NMOS model. ● 500W !? ● Worked for a long time trying to optimize package, gate drive, etc. ● Turns out I’m being autotrolled by the thermal modelling, which is represented by voltage and current sources.