HBBPFC international project new design

DESCRIPTION

Power factor correctors or PFCs are developed as a solution to power consumption problems due to their high power factor, protect systems against voltage fluctuations and high currents [1], [2].

The purpose of a PFC is that the input current follows the sinusoidal form of the line voltage, so that its unit power factor is obtained [1], [2].

The new HBBPFC is a converter designed to obtain 450VDC output (400VDC in the first converter), powered from the mains and obtaining a power factor PF = 1.

FIRST DESIGN

This project has three printed circuits designed in Altium Designer, the first, the power stage or HBBPFC, the second, the signal conditioning stage with the control stage and, finally, the supply stage and its implementations were:

Figure 1: HBBPFC international project global implementation.

EXPERIMENTAL RESULTS

The following figures correspond to some of the results obtained in the implementation of the HBBPFC:

Figure 2: HBBPFC international project global testing [1].

Figure 3: HBBPFC international project Power Factor visualization [1].

Output voltage (vs) = 212.3 + 212.7 = 425V

PF = 1.

Power output = 83W.

NEW DESIGN

In [3] a new design of the signal conditioning PCB was proposed because the DSP used for the implementation of the control stage was obsolete, for this reason, PSoC creator became the new programming environment to develop the controller of the HBBPFC, with a development card based on FPGA with reference CY8CKIT-059 PSoC 5LP CY8C5888LTI_LP097.

When changing the programming environment, the operating point of the HBBPFC was changed, increasing its voltage to 450VDC maintaining the power factor (PF = 1). The new implementation of this rectifier with power factor correction is observed in detail below:

Figure 4: HBBPFC new implementation side view.

Figure 5: HBBPFC new implementation top view.

Figure 6: HBBPFC new implementation global view.

In the upper part is the printed circuit that has the supply of voltages and the control stage (signal conditioning included), the other PCB is the power circuit (topology of the HBBPFC) and the lower part is the resistive load.With this new design, the result is a unit power factor with a power greater than 100W, as shown in the following figures:

Figure 7: waveform of the current and input voltage with measurement of power factor and power of the converter.

Figure 8: output voltage of HBBPFC.

In summary, with the new design of the HBBPFC the power of the converter is increased maintaining its control of power factor. 

REFERENCES

[1] A. G. Rubiano-Muñoz. “módulo de interconexión entre una fuente para DBD y la red eléctrica”. Andy Rubiano™, pp. 1 - 110. May 2017.

[2] A. G. Rubiano-Muñoz. “HBBPFC design and implementation”. Andy Rubiano™,. Recuperated on september 9th of 2017, 2017. [Online]. Available: https://www.pcbway.com/project/sponsor/HBBPFC_design_and_implementation_project.html

[3] A. G. Rubiano-Muñoz. “New signal conditioning stage for HBBPFC”. Andy Rubiano™,. Recuperated on december 21th of 2017, 2017. [Online]. Available: https://www.pcbway.com/project/sponsor/New_signal_conditioning_stage_for_HBBPFC.html

Words to PCBWay

Thanks PCBWay and Anson Bao for their great help and support during the development of this ambitious project.

Andy Rubiano™ 

Electronic engineer. All Rights reserved.

Twitter: @RubianoAndy.

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