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Sat
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« on: October 10, 2015, 04:57:20 04:57 »

Hi Guys,


How to convert 400V DC to 5000VDC with 1.0A load (5000W), with out using  iron core transformer,( is it possible with  phase shifted full bridge converter)...?


Thanks,
Sat



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OscarH
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« Reply #1 on: October 10, 2015, 02:25:34 14:25 »

Sat,
I believe the 5 kW power needed is a serious obstacle.
I have done in the past such a high frequency converter with non-iron torus, but it was for a couple of milli-amps, not amps.
The input stage will have to drive around 15 amps, which is not impossible, but not usual.
I'm also wondering if the size of the torus to avoid core saturation is a reasonnable size.

Let's see if other forum's members have insight experience.

Cheers. OH
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Sat
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« Reply #2 on: October 11, 2015, 06:06:54 06:06 »

Assume if it is non isolated converter, polyphase or interleaved boost converter can fit this requirement but 5000V diode and MOSFET are not available.

Let's see  any other ideas from forum members
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Signal
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« Reply #3 on: October 11, 2015, 01:12:53 13:12 »

I had not ever solved such task - just thoughts to participate...

Inverter on kHz followed by Cockcroft–Walton generator? We know nothing about load and its requirements. Is it constant? Does it need regulated supply? Galvanic isolation? etc.
The same way I can only guess the source of "initial" 400V DC. Is it stable or just rectified mains?
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Gallymimu
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« Reply #4 on: October 11, 2015, 05:51:17 17:51 »

We used to design 20KW mid frequency RF supplies for the vacuum coating industry.  It's a big project.  It cost about $1m USD running with a very lean team to develop the product.

We did it with a full bridge resonant LLC converter.  We designed custom solenoid transformers with loosely coupled ferrite cores (that way only ONE transformer created both 'L's in the LLC.  It was pretty cool.  The supply used fixed duty cycle and variable frequency to control the power delivered.
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