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High Frequency High Power Full Bridge Converter for Plasma Torches

This content has been downloaded from IOPscience. Please scroll down to see the full text. 2017 J. Phys.: Conf. Ser. 789 012021 (http://iopscience.iop.org/1742-6596/789/1/012021) View the table of contents for this issue, or go to the journal homepage for more Download details: IP Address: 167.88.99.142 This content was downloaded on 11/02/2017 at 16:48 Please note that terms and conditions apply.

You may also be interested in: Plasma Modeling: Radio frequency inductively coupled discharges in thermal plasmas G Colonna and A D’Angola Synthesis of Titania Nanoparticles Using a Compact Nonequilibrium Plasma Torch Mingwei Li, José Gonzalez-Aguilar and Laurent Fulcheri A Ceramic Plasma Torch for Determining Silicon Content in HF Solutions Plasma Atomic Emission Spectrometry Atsuko Matsubara, Hisao Kojima, Toshihiko Itoga et al.

by Inductively Coupled

Effects of Nozzle Configuration on Flow Characteristics inside DC Plasma Torch X. Q. Yuan, H. Li, T. Z. Zhao et al. Characteristics of a DC-Driven Atmospheric Pressure Air Microplasma Jet Jaegu Choi, Keita Matsuo, Hidekazu Yoshida et al. Oyster Shell Recycling and Bone Waste Treatment Using Plasma Pyrolysis Jae Ou Chae, S P Knak, A N Knak et al. Long arc stabilities with various arc gas flow rates K Maruyama, K Takeda, M Sugimoto et al. A low current–high voltage compact arc plasma torch L Fulcheri, J-D Rollier and J Gonzalez-Aguilar Dynamical investigation and parameter stability region analysis of a flywheel energy storage system in charging mode Zhang Wei-Ya, Li Yong-Li, Chang Xiao-Yong et al.

LTP2016 IOP Conf. Series: Journal of Physics: Conf. Series 789 (2017) 012021

IOP Publishing doi:10.1088/1742-6596/789/1/012021

International Conference on Recent Trends in Physics 2016 (ICRTP2016) IOP Publishing Journal of Physics: Conference Series 755 (2016) 011001 doi:10.1088/1742-6596/755/1/011001

High Frequency High Power Full Bridge Converter for Plasma Torches A Hakki1 , K Sadikov1, N Kashapov1 1 Physical Institute, Kazan (Volga-Region) Federal University, 420008, Kremlyovskaya St, bdg.18, Kazan, Russia E-mail: [email protected]

Abstract. This paper presents a full bridge converter with a high speed rectifier and filter for plasma torches. Full bridge circuit with high frequency pulse width modulation control is used and high frequency transformer to insulate is adopted. For Argon (Ar) gas Plasma Torches, and by increasing the pulse width the average power consumption has modified from 1KW to 5.6KW (positive load). For Nitrogen (N2) gas Plasma Torches, and by increasing the pulse width the average power consumption has reduced from 7.7KW down to 3KW (negative load). For the Plasma Torches load the frequency of converter was steady at

Key words. Full Bridge Converters, Power Pulse, Mosfet, Filters, Plasma Torches

1. Introduction Full bridge converters are recommended to use for high power applications. There are many applications for pulse power supplies. This paper provides a new method to improve the performance and flexibility for pulse power supplies .This design includes using proper adjustment and full bridge converter to obtain the output voltage with rapid raising time. The output voltage in this method depends on the width of pulse control signals. The control circuit for this full bridge converters is very simple and cheap, high frequency full bridge converters using ferrite material core for transformers and very fast power Mosfet transistors as switches, so these kind of power supplies are small size, compatible, and the efficiency factor is very high [1,2,3].

2. Experimental Setup Fig. 1. Shows the schematic of plasma torches power supply, when Switch Q1 and Q3 turns on, current flows from through Q1, primary of transformer , and Q3 to ground. At the same time the current flows in the secondary and gets rectified and filtered. When Q2 and Q4 turns on current flows from through Q2 primary of transformer , and Q4 and to ground, the voltage is reflected to the secondary proportional to the turns ratio. The rectified voltage is filtered. The current though the transformer primary reverses every alternate half cycle. When a short circuit happens at the output load (in this case the feedback voltage should be more than 4V) the current transformer will sensor this short and the control unit will automatically stops generate the pulses ( , so this circuit is protected from short circuit. For the transformers T2, T3 turns ratio , the maximum amplitude of signals driver is . To start plasma process it need a one high voltage pulse, the

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI. Published under licence by IOP Publishing Ltd 1

LTP2016 IOP Conf. Series: Journal of Physics: Conf. Series 789 (2017) 012021

IOP Publishing doi:10.1088/1742-6596/789/1/012021

control unit generates the pulse , and then the ignition circuit will give a high voltage pulse, the amplitude of this pulse is about 6KV , the width is about , the amplitude and the width of ignition pulse depend on the parameters of plasma chamber [4,5,6].

Figure 1. Schematic of Plasma Torches Power Supply The output voltage

is given by

3. Results and discussion ∫

Fig. 2. shows the currents of primary and secondary of transformer [7,8].

(

.

√

(

∫

√

√

∫

(

√ Where

,

Figure 2. RMS currents

2

LTP2016 IOP Conf. Series: Journal of Physics: Conf. Series 789 (2017) 012021

∫

( ∫

)

Where is the width of pulse shown in Fig. 4.

IOP Publishing doi:10.1088/1742-6596/789/1/012021

In our case Delay time (death time) Note that during delay time are in cut off situation.

, all transistors

as Target efficiency of full bridge converter

Where is the turns ratio of the transformer . In this case

Input power Assuming 90% Efficiency the input power is:

Working frequency:

Maximum average Input current:

Input DC voltage

Parameters of the HF transformer Where phase to phase voltage. by changing the period (the width of pulses ) regulate the output voltage value.

the core of the transformer material.

must be ferrite

, Parameters Where is the magnetic constant, A area of one loop, n number of turns, the output resistance. Thus, the load current is determined by the formula:

The value 535 V 570 V 500 V 550 V 17 A 50 KHz

ɳ

Finally the output current is given by:

3

90% 0.45

LTP2016 IOP Conf. Series: Journal of Physics: Conf. Series 789 (2017) 012021

IOP Publishing doi:10.1088/1742-6596/789/1/012021

4. Conclusion In short, the working region of the plasma torches can be in the forward conduction region (positive resistor), or in the reverse region (negative resistor), for Argon gas (Ar) plasma, and by increasing the pulse width the average power consumption has modified from 1KW to 5.6KW (positive load) [9-16]. For Nitrogengas (N2) plasma, and by increasing the pulse width the average power consumption has reduced from 7.7KW down to 3KW (negative load). for the both plasma load (Ar,N2) the frequency of full bridge converter was steady at In other words, by varying the value of resister (Rv) showing in fig.1 the load current can be adjusted. References [1]

[2]

[3]

[4] [5] [6] [7] [8]

[9] [10] [11] [12] [13] [14] [15] [16]

Schonknecht A., De Doncker R., Novel Topology for Parallel Connection of Soft-Switching High-Power High-Frequency Inverters, IEEE Transactions on Industry Applications, Vol. 39, (2003), 550 – 555 D. Aggeler, J. Biela, and J. W. Kolar, “A compact, high voltage 25 kW, 50 kHz DC-DC converter based on sic jfets,” in Proc. Twenty-Third Annual IEEE Applied Power Electronics Conference and Exposition APEC 2008, 24–28 Feb. 2008, pp. 801–807. K. A. Alberto Guerra and S. Fimiani, “Ultra-fast recovery diodes meet todays requirements for high frequency operation and power ratings in smps applications,” International Rectifier, Tech. Rep., 2000. R. Severns (2005). Design of Snubbers for Power Circuits. Available from: http://www.cde.com/tech/design.pdf F. Wang, A. Kuthi, and M. A. Gundersen, “Compact high repetition rate pseudo spark pulse generator,” vol. 33, no. 4, pp. 1177–1181, Aug. 2005. Magnetic Core. Wikipedia, Available from: http://en.wikipedia.org/wiki/Magnetic_core, (2010). Design of Planar Power Transformers. Ferroxcube, Available from: http://www.ferroxcube.com/appl/info/plandesi.pdf K. Venkatachalam, C. R. Sullivan, T. Abdallah, and H. Tacca, “Accurate prediction of ferrite core loss ith nonsinusoidal waveforms using only steinmetz parameters,” in Proc. IEEE Workshop on Computers in Power Electronics, 3–4 June 2002, pp. 36–41. Gavrilova V A, Fazlyyyakhmatov M G and Kashapov N F 2013 J. Phys.: Conf. Ser. 479 012010 Fayrushin I, Kashapov N and Dautov I 2014 J. Phys.: Conf. Ser. 567 012009 Kashapov L N, Kashapov N F and Kashapov R N 2013 J. Phys.: Conf. Ser. 479 012011 Kashapov L N, Kashapov N F and Kashapov R N 2014 J. Phys.: Conf. Ser. 567 012025 Zaripov R G, Kashapov N F, Tkachenko L A and Shaydullin L R 2016 J. Phys.: Conf. Ser. 669 012053 Denisov D G, Kashapov N F and Kashapov R N 2015 IOP Conference Series: Materials Science and Engineering 86 012005 Saifutdinov A I, Fairushin I I and Kashapov N F 2016 JETP Lett. 104 180–185 Sadikov K, Fayrushin I, Shamsutdinov A, Kashapov N 2016 J. Phys.: Conf. Ser. 669 012048

4

Search

Collections

Journals

About

Contact us

My IOPscience

High Frequency High Power Full Bridge Converter for Plasma Torches

This content has been downloaded from IOPscience. Please scroll down to see the full text. 2017 J. Phys.: Conf. Ser. 789 012021 (http://iopscience.iop.org/1742-6596/789/1/012021) View the table of contents for this issue, or go to the journal homepage for more Download details: IP Address: 167.88.99.142 This content was downloaded on 11/02/2017 at 16:48 Please note that terms and conditions apply.

You may also be interested in: Plasma Modeling: Radio frequency inductively coupled discharges in thermal plasmas G Colonna and A D’Angola Synthesis of Titania Nanoparticles Using a Compact Nonequilibrium Plasma Torch Mingwei Li, José Gonzalez-Aguilar and Laurent Fulcheri A Ceramic Plasma Torch for Determining Silicon Content in HF Solutions Plasma Atomic Emission Spectrometry Atsuko Matsubara, Hisao Kojima, Toshihiko Itoga et al.

by Inductively Coupled

Effects of Nozzle Configuration on Flow Characteristics inside DC Plasma Torch X. Q. Yuan, H. Li, T. Z. Zhao et al. Characteristics of a DC-Driven Atmospheric Pressure Air Microplasma Jet Jaegu Choi, Keita Matsuo, Hidekazu Yoshida et al. Oyster Shell Recycling and Bone Waste Treatment Using Plasma Pyrolysis Jae Ou Chae, S P Knak, A N Knak et al. Long arc stabilities with various arc gas flow rates K Maruyama, K Takeda, M Sugimoto et al. A low current–high voltage compact arc plasma torch L Fulcheri, J-D Rollier and J Gonzalez-Aguilar Dynamical investigation and parameter stability region analysis of a flywheel energy storage system in charging mode Zhang Wei-Ya, Li Yong-Li, Chang Xiao-Yong et al.

LTP2016 IOP Conf. Series: Journal of Physics: Conf. Series 789 (2017) 012021

IOP Publishing doi:10.1088/1742-6596/789/1/012021

International Conference on Recent Trends in Physics 2016 (ICRTP2016) IOP Publishing Journal of Physics: Conference Series 755 (2016) 011001 doi:10.1088/1742-6596/755/1/011001

High Frequency High Power Full Bridge Converter for Plasma Torches A Hakki1 , K Sadikov1, N Kashapov1 1 Physical Institute, Kazan (Volga-Region) Federal University, 420008, Kremlyovskaya St, bdg.18, Kazan, Russia E-mail: [email protected]

Abstract. This paper presents a full bridge converter with a high speed rectifier and filter for plasma torches. Full bridge circuit with high frequency pulse width modulation control is used and high frequency transformer to insulate is adopted. For Argon (Ar) gas Plasma Torches, and by increasing the pulse width the average power consumption has modified from 1KW to 5.6KW (positive load). For Nitrogen (N2) gas Plasma Torches, and by increasing the pulse width the average power consumption has reduced from 7.7KW down to 3KW (negative load). For the Plasma Torches load the frequency of converter was steady at

Key words. Full Bridge Converters, Power Pulse, Mosfet, Filters, Plasma Torches

1. Introduction Full bridge converters are recommended to use for high power applications. There are many applications for pulse power supplies. This paper provides a new method to improve the performance and flexibility for pulse power supplies .This design includes using proper adjustment and full bridge converter to obtain the output voltage with rapid raising time. The output voltage in this method depends on the width of pulse control signals. The control circuit for this full bridge converters is very simple and cheap, high frequency full bridge converters using ferrite material core for transformers and very fast power Mosfet transistors as switches, so these kind of power supplies are small size, compatible, and the efficiency factor is very high [1,2,3].

2. Experimental Setup Fig. 1. Shows the schematic of plasma torches power supply, when Switch Q1 and Q3 turns on, current flows from through Q1, primary of transformer , and Q3 to ground. At the same time the current flows in the secondary and gets rectified and filtered. When Q2 and Q4 turns on current flows from through Q2 primary of transformer , and Q4 and to ground, the voltage is reflected to the secondary proportional to the turns ratio. The rectified voltage is filtered. The current though the transformer primary reverses every alternate half cycle. When a short circuit happens at the output load (in this case the feedback voltage should be more than 4V) the current transformer will sensor this short and the control unit will automatically stops generate the pulses ( , so this circuit is protected from short circuit. For the transformers T2, T3 turns ratio , the maximum amplitude of signals driver is . To start plasma process it need a one high voltage pulse, the

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI. Published under licence by IOP Publishing Ltd 1

LTP2016 IOP Conf. Series: Journal of Physics: Conf. Series 789 (2017) 012021

IOP Publishing doi:10.1088/1742-6596/789/1/012021

control unit generates the pulse , and then the ignition circuit will give a high voltage pulse, the amplitude of this pulse is about 6KV , the width is about , the amplitude and the width of ignition pulse depend on the parameters of plasma chamber [4,5,6].

Figure 1. Schematic of Plasma Torches Power Supply The output voltage

is given by

3. Results and discussion ∫

Fig. 2. shows the currents of primary and secondary of transformer [7,8].

(

.

√

(

∫

√

√

∫

(

√ Where

,

Figure 2. RMS currents

2

LTP2016 IOP Conf. Series: Journal of Physics: Conf. Series 789 (2017) 012021

∫

( ∫

)

Where is the width of pulse shown in Fig. 4.

IOP Publishing doi:10.1088/1742-6596/789/1/012021

In our case Delay time (death time) Note that during delay time are in cut off situation.

, all transistors

as Target efficiency of full bridge converter

Where is the turns ratio of the transformer . In this case

Input power Assuming 90% Efficiency the input power is:

Working frequency:

Maximum average Input current:

Input DC voltage

Parameters of the HF transformer Where phase to phase voltage. by changing the period (the width of pulses ) regulate the output voltage value.

the core of the transformer material.

must be ferrite

, Parameters Where is the magnetic constant, A area of one loop, n number of turns, the output resistance. Thus, the load current is determined by the formula:

The value 535 V 570 V 500 V 550 V 17 A 50 KHz

ɳ

Finally the output current is given by:

3

90% 0.45

LTP2016 IOP Conf. Series: Journal of Physics: Conf. Series 789 (2017) 012021

IOP Publishing doi:10.1088/1742-6596/789/1/012021

4. Conclusion In short, the working region of the plasma torches can be in the forward conduction region (positive resistor), or in the reverse region (negative resistor), for Argon gas (Ar) plasma, and by increasing the pulse width the average power consumption has modified from 1KW to 5.6KW (positive load) [9-16]. For Nitrogengas (N2) plasma, and by increasing the pulse width the average power consumption has reduced from 7.7KW down to 3KW (negative load). for the both plasma load (Ar,N2) the frequency of full bridge converter was steady at In other words, by varying the value of resister (Rv) showing in fig.1 the load current can be adjusted. References [1]

[2]

[3]

[4] [5] [6] [7] [8]

[9] [10] [11] [12] [13] [14] [15] [16]

Schonknecht A., De Doncker R., Novel Topology for Parallel Connection of Soft-Switching High-Power High-Frequency Inverters, IEEE Transactions on Industry Applications, Vol. 39, (2003), 550 – 555 D. Aggeler, J. Biela, and J. W. Kolar, “A compact, high voltage 25 kW, 50 kHz DC-DC converter based on sic jfets,” in Proc. Twenty-Third Annual IEEE Applied Power Electronics Conference and Exposition APEC 2008, 24–28 Feb. 2008, pp. 801–807. K. A. Alberto Guerra and S. Fimiani, “Ultra-fast recovery diodes meet todays requirements for high frequency operation and power ratings in smps applications,” International Rectifier, Tech. Rep., 2000. R. Severns (2005). Design of Snubbers for Power Circuits. Available from: http://www.cde.com/tech/design.pdf F. Wang, A. Kuthi, and M. A. Gundersen, “Compact high repetition rate pseudo spark pulse generator,” vol. 33, no. 4, pp. 1177–1181, Aug. 2005. Magnetic Core. Wikipedia, Available from: http://en.wikipedia.org/wiki/Magnetic_core, (2010). Design of Planar Power Transformers. Ferroxcube, Available from: http://www.ferroxcube.com/appl/info/plandesi.pdf K. Venkatachalam, C. R. Sullivan, T. Abdallah, and H. Tacca, “Accurate prediction of ferrite core loss ith nonsinusoidal waveforms using only steinmetz parameters,” in Proc. IEEE Workshop on Computers in Power Electronics, 3–4 June 2002, pp. 36–41. Gavrilova V A, Fazlyyyakhmatov M G and Kashapov N F 2013 J. Phys.: Conf. Ser. 479 012010 Fayrushin I, Kashapov N and Dautov I 2014 J. Phys.: Conf. Ser. 567 012009 Kashapov L N, Kashapov N F and Kashapov R N 2013 J. Phys.: Conf. Ser. 479 012011 Kashapov L N, Kashapov N F and Kashapov R N 2014 J. Phys.: Conf. Ser. 567 012025 Zaripov R G, Kashapov N F, Tkachenko L A and Shaydullin L R 2016 J. Phys.: Conf. Ser. 669 012053 Denisov D G, Kashapov N F and Kashapov R N 2015 IOP Conference Series: Materials Science and Engineering 86 012005 Saifutdinov A I, Fairushin I I and Kashapov N F 2016 JETP Lett. 104 180–185 Sadikov K, Fayrushin I, Shamsutdinov A, Kashapov N 2016 J. Phys.: Conf. Ser. 669 012048

4