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Author Topic: [Req] 12kW, 5KV Capacitor Charging Power supply design Help  (Read 600 times)
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itp
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« on: July 30, 2016, 06:51:24 18:51 »

Hi All,
I have to design and develop a 12kW, 5 KV Capacitor Charging Power supply for a client. A resonant converter topology is preferable. Experience persons Kindly suggest tutorials/links/simulation software etc.

Thanks and regards
Itp
« Last Edit: July 31, 2016, 12:55:53 12:55 by itp » Logged
medik
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« Reply #1 on: August 08, 2016, 07:21:43 07:21 »

I have seen a boost dc dc converter of 12kW at 400V 30A Max. From your requirements less than 3A is needed.
 I advise that you build a scaled down version of say 500W before going to experiment with high 12kW.

You did not state the input voltage source and level. Is it going to run off batteries?
« Last Edit: August 08, 2016, 07:24:31 07:24 by medik » Logged
itp
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« Reply #2 on: August 08, 2016, 04:56:11 16:56 »

Hi medik,

It will be operated from three-phase (420V) supply.

Regards
itp
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roscoe
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« Reply #3 on: October 01, 2016, 02:27:55 02:27 »

There are a few approaches that could work here -- you could use something like a SEPIC style boost w/ a transformer and then a ladder multiplier.  You probably don't care *too* much about ripple since you're just charging caps.  The downside is that it will take a while to charge them like this.

Alternatively, you could look for an IGBT and switch rectified voltage.
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Gallymimu
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« Reply #4 on: October 06, 2016, 12:57:05 00:57 »

I've built these before.  The best design is resonant as you suggest so you can take advantage of high queue to get the MANY X boost you need.  This is NOT a trivial design.

The last time I did it was 15KW from 208V 3  phase input for 800V output, open circuit however it was 5000V.

A trick you can use with LLC is that you can get both Ls in one leakly solenoid (leakage inductance makes one L and magetizing inductance makes the other)  full bridge IGBT resonant 100KHz to 500KHz worked out well for us.

It was a beast of a design and cost about $1m to develop.  Granted it had a graphical UI, industrial comm protocols, 1% measurement and accuracy, and could survive high frequency plasma arcs on the output (very low stored energy output).

I hope you are a VERY experienced power designer.  This is NOT an easy design.

Also be careful of corona, you will have a problem with it on the edges of traces of our PCB outer layers.
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itp
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« Reply #5 on: October 07, 2016, 09:30:14 09:30 »

Hi all,
Can you suggest any published journal papers on this topic. Searching on google will definitely fetch lot of results. But I would rather prefer Experts in this field suggest some relevant papers.

Thanks and regards
Itp
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Sat
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« Reply #6 on: October 07, 2016, 01:06:25 13:06 »

Hi Itp,

Use two stage power conversion for your application (AC to DC front end converter for 420Vac to 800 VDC conversion. A ZVS phase shifted interleaved fullbridge for 800VDC to 5KVDC)   

Try  VIENNA rectifier for front end converter purpose.

https://en.wikipedia.org/wiki/Vienna_rectifier

Use multiple outputs in fullbridge (8 outputs, each output voltage is 625V). After rectification add all these outputs in series connection to get 5KV.

i hope your are expert in power electronics design, because it is very tough requirement. I suggest to you initially make a scale down (1.2KW) prototype.

Thanks,
Sat
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