4/28/2023 0 Comments Unfolder inverterThe FCML topology can be heavily optimized to utilize switches with ratings lower than the dc bus voltage. Finally, an exploration of the boundary condition of converter start-up is performed. Therefore, they are able to be contract-manufactured, yet still achieve excellent power density figures. All of the major power boards in this system are designed to be constructed with commercial parts and conventional manufacturing techniques. In the full system prototype, a power level of 6.1 kW is achieved, running in the dc-ac mode from 400 Vdc to 240 Vac and a system density of 201 W/in^3 (12.3 W/cm^3) is reported, which includes the cold plate in a liquid-cooled thermal management system. The system is then verified operational in both the PFC and the inverter modes. Again, the Level II power level necessitated a parallel design, which we prefer to interleave, so the resultant bidirectional electric vehicle charger design has two FCML stages in parallel as the boost PFC stage as well as two SSB stages in parallel as the energy buffer stage. The SSB topology is then added to the system in a full redesign that integrates all of the components into a package with high utilization of 3-D space. Mechanical design and thermal management implications are considered in the construction of the FCML prototype, which achieved Level II power levels with a custom-designed air-cooled heatsink prototype. In order to achieve the required power level, an interleaved 6-level FCML is designed and built. The FCML topology is verified at Level II charging power levels. This work proposes the use of the flying-capacitor multilevel (FCML) topology in order to greatly shrink the boost inductor, which is then integrated with the series-stacked buffer (SSB) topology to greatly shrink the buffer capacitors. Running these functions in reverse provides inverter (dc-ac) functionality, where the rectifier and boost PFC stage is now acting as a rectified sine-wave generator and unfolder inverter stage. The prototypical conventional system discussed in this work consists of a rectifier followed by a two-switch power converter shaping the input current through a physically-large boost inductor the power ripple is then buffered by a physically-large electrolytic capacitor bank. Second, because the input ac current and voltage multiply and result in a twice-line frequency power pulsation, this pulsation must be managed with an energy buffer. First, the input ac current must be shaped to match both the shape and the phase of the input ac voltage, the power factor correction (PFC) function. ![]() Using a Level II single-phase bidirectional electric vehicle charger as a demonstration system, this work focuses on strategies that promote minimization of passive component sizes through the application of different electrical topologies, as well as the mechanical and thermal implications of such applications.Ī conventional system design is presented as the baseline for improvement: in a single-phase ac-dc converter system, there exists two major functions that must be performed. In this dissertation, methods of improving overall power electronic system density are developed and explored.
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