Jpe 8-2-1
Jpe 8-2-1
Jpe 8-2-1
JPE 8-2-1
†*
Dept. of Electrical and Electronics Eng., Indian Institute of Technology, Delhi, New-Delhi, India
ABSTRACT
In this paper, a novel delta/double-fork transformer based 18-pulse full-wave AC-DC converter is designed, modeled,
simulated and developed to feed isolated DC varying loads. The proposed AC-DC converter is used for low voltage and
large current DC loads in applications such as electrowinning, where isolation is required mainly for stepping down the
supply voltage. The proposed converter improves power quality at AC mains and meets IEEE-519 standard requirements
at varying loads.
and transformer utilization. Each group commutates by together as shown in Fig. 2 to make a full-wave 12-pulse
itself so that the diode conduction period is 120°. The IPR AC-DC converter. Maslin et. al.[5] reported a 12-phase
absorbs the instantaneous voltage difference between the full-wave AC-DC converter based on zigzag transformers
two commutating groups and allows them to operate for electrical induction apparatus as early as 1943. This
independently. twelve-pulse converter uses two three-phase transformers
It is a common practice to use multiple 12-pulse or having star and delta primary windings but identical
18-pulse AC-DC converter units fed from such zigzag secondary windings. This rectifier configuration is
phase–staggered transformers to meet IEEE-519 standard reported to use seven interphase reactors. However, it is
[2]
requirements as the total harmonic distortion (THD) of observed that the total harmonic distortion (THD) of the
the input line currents of a single unit is high and may not input current is more than 8% in all these cases and tuned
qualify as clean power at high loads. The isolation passive filters are extensively used.
transformers used for high currents can have different ANSI 45 and ANSI 46 rectifier combinations are also
winding arrangements such as star, delta, fork, zig-zag, described by Brown[6] for the copper electrowinning
and polygon. The isolation transformers used for industry. A twelve-pulse full-wave AC-DC converter fed
full-wave rectifiers generally have delta or star primary from transformers with delta and polygon primary
windings (sometimes polygon windings also) and star, windings is also described by Wiechmann et. al.[7] for the
zigzag or fork secondary windings. The star, zigzag and same application. A novel transformer connection in
fork windings provide a neutral point for full-wave which primary windings of different transformers are
rectifiers; however, two secondary windings must have connected in series and identical secondary windings for
interphase reactors between neutral points as shown in Fig. full-wave rectification is described by Oliver et. al.[8] that
1. Unfortunately, a six-phase full-wave AC-DC converter doesn’t require IPRs. However, it has complex primary
affects the power quality at the point of common coupling winding connections for higher pulse numbers and a
(PCC) by injecting harmonics into AC mains and, thus, greater number of transformers are needed, thereby
affecting the neighbouring consumers. Due to this reason making reliability of the system poor. Miyari et. al.[9] have
ANSI 45 and ANSI 46 transformers [3-4] are employed explained a method of pulse multiplication in 6-pulse
An 18-Pulse Full-Wave AC-DC Converter for … 111
full-wave rectifiers but it adds one more semiconductor other and at 00 and +200 respectively from voltage VR,
device in the path of the load current. An 18-pulse diode where VR is the secondary voltage phasor in the direction
bridge based front end AC-DC converter for electrolytic
applications is explained by Wiechmann et. al.[10]. This
topology also has two devices in the path of the load
current and, hence, additional voltage drop and losses,
which are not desired on the secondary side, as the load
current is very large.
In this paper a novel 18-phase full-wave AC-DC
converter is proposed for low-voltage high current
applications. The developed 18-pulse rectifier is fed from
a delta/fork-fork transformer. The input transformer
secondary winding is a symmetric fork extending two sets
of 9-phases for the two nine-diode full-wave converters. A
detailed design of the transformer and resulting 18-pulse
diode rectifier system is carried out to study the behavior
of this converter. The designed converter system is Fig. 2 A delta/double star transformer (ANSI 45) and star/
double star transformer (ANSI 46) combination for
modeled and simulated in MATLAB to demonstrate 12-pulse full-wave AC-DC conversion
power quality improvement at AC mains. A prototype is
developed in the laboratory to validate the proposed model iA
B11
of the supply phase voltage VA. The number of turns in VB19 = K 1VR − K 3 VR ∠ - 120° (5)
every winding is determined as a function of the required
VB12 = K 1VR − K 3 VR ∠120° (6)
secondary voltage, VR. These secondary voltages, as
Eqns. (4-6) give the values of constants K1 to K3 for
marked in Fig. 4, are expressed by the following
desired phase shift as
relationships.
Let the transformation ratio of the transformer be a,
K1 = 0.3949, K 2 = 0.6051, K 3 = 0.7422 (7)
a = VA / V R (1)
2.2 Transformer rating for the 18-Pulse AC-DC
converter
The required voltages for the converter I (FW1) are:
The rating of a transformer is dependent on the voltage
across each winding and the current through them. The
VB11 = VR ∠00 , VB12 = VR ∠ − 400 , VB13 = VR ∠ − 800 ,
(2) winding voltages determine the core size while the
VB14 = VR ∠ − 1200 , VB15 = VR ∠ − 1600 , VB16 = VR ∠ − 2000 ,
currents determine the conductor size and, hence, the two
VB17 = VR ∠ − 2400 , VB18 = VR ∠ − 2800 , VB19 = VR ∠ − 3200
determine its equivalent VA rating [11]. The VA rating of
these transformers is calculated as:
The required voltages for the converter II (FW2) are:
VA rating = 0.5 ∑ (Vk I k) (8)
VB21 = VR ∠200 , VB22 = VR ∠ − 200 , VB23 = VR ∠ − 600 ,
VB24 = VR ∠ − 1000 , VB25 = VR ∠ − 1400 , VB26 = VR ∠ − 1800 , (3)
Where, Vk and Ik are the root-mean-square (r.m.s.) value
0 0 0
VB27 = VR ∠ − 220 , VB28 = VR ∠ − 260 , VB29 = VR ∠ − 300 of the voltage across and current through the kth winding.
The same relation is used for estimating the transformer
The values of constants K1 to K3 marked in Fig. 4a rating of this 18-pulse AC-DC converter.
determine the secondary winding turns as a fraction of The mathematical analysis of the different converters
primary windings turns. These values can be determined gives the following power rating [11]:
by solving the following equations: The rating of the full-wave double star connection
converter (without interphase reactor) is 154%.
VB11 = ( K 1 + K 2 )VR (4) The rating of the ANSI 45, 6-Pulse converter
connection is 126.5%.
Fig. 4b Graphical representation of delta/double fork transformer secondary windings for 18-pulse AC-DC converter and phasor
diagram
An 18-Pulse Full-Wave AC-DC Converter for … 113
The rating of the ANSI 45 and 46, 12-pulse Each diode in the 18-pulse AC-DC converter conducts
combination converter is 126.5%. for 40° in sequential manner. Therefore, the windings of
The rating of the Zigzag 12 pulse AC-DC converter is the transformer in Fig. 4a corresponding to segment
133%. lengths K2 and K3 have diode current flowing through them
The power rating of the proposed transformer can be which is due to conduction as well as induction. However,
estimated by referring to Fig. 4 as follows: the current through the K1 length winding is flowing for
Let us assume that the secondary output phase voltage 120° as it carries current due to induction only. When
of each group in Fig. 4 is VR. these currents are transformed to the primary side, their
Then the peak voltage of the rectified sine wave is: value will change in the primary to secondary winding
2 VR sin 80°=1.393VR (It is the peak of the sine wave voltage ratio. These transformed currents are shown in Fig.
segment that is the average of two full-wave rectified 5b. These currents, when added, become the primary
output ripples of 40° each). winding current which is shown in Fig. 5c. The difference
The output voltage at no load, of the two delta winding currents is the AC mains input
current that is shown in Fig. 5d. The AC mains current has
VDC0= 18 steps and their values are indicated in the Fig. 5, which
100°
1 helps in determining its r.m.s. value.
(1.393 VR )
(20°π 180°) ∫ sin(ωt)d(ωt) = 1.385V
80°
R (9)
The average current per diode is (Idc/18) (assuming a
rectangular current waveform).
So, the peak diode current is Idc/2.
Fig. 5 The ideal values of primary winding current (iAC) and input AC mains current (iA) in proposed 18-pulse full-wave AC-DC
converter
114 Journal of Power Electronics, Vol. 8, No. 2, April 2008
40 ° 40 ° 40 ° ⎞
I CA = ( I dc / 2 )2 ⎛⎜ K 12 + (K 1 + K 2 ) 2 + (K 1 + K 2 + K 3 ) 2 ⎟
⎝ 180 ° 180 ° 180 ° ⎠
= 0.4825 I dc
(11)
The results are recorded using the ‘Fluke 43B’ Power converter at light load (20% of full-load). The current
Quality Analyzer and the power quality indices so waveform of the AC mains, its harmonic spectrum and the
obtained are tabulated in Table 3. The recorded waveforms THD of the six-pulse AC-DC converter at light load are
for light load and full-load are shown in Fig. 14. shown in Fig. 8(b). The waveforms and the input current
harmonic spectrum at full load for the 6-pulse AC-DC
5. Results and discussion converter are shown in Figs. 9(a) and 9(b), respectively.
The THDi is of the order of 18.51% at full-load which is
The power quality indices obtained from simulations of not acceptable as per IEEE-519 Standard requirements.
the 6-pulse, 12-pulse and the proposed 18-pulse AC-DC Fig. 10(a) shows the input AC phase voltage VA, input
converters are given in Table 2. The various waveforms of AC current iA, output DC voltage Vdc, and load current idc
the 18-pulse converter transformer are shown in Fig. 7 at waveforms of the 12-pulse AC-DC converter at light load.
light load to make the steps visible. It can be seen that the Fig. 10(b) shows the AC mains current waveform iA and
input current (iA) has 18 steps in one cycle of AC supply. its harmonic spectrum. The harmonic spectrum clearly
Two primary winding currents iAB and iCA are shown
shows that the 11th and 13th are the dominant harmonics
whose algebraic sum is the supply current (iA). Moreover,
and the THD of the AC mains current (THDi) is 10.05% at
there are the secondary winding currents (iK1, ik2, iB15 and
light load. Fig. 11 shows the performance of the 12-pulse
iB16, where iB15 means the current in the transformer
winding connected at B15) which results in idc1. The
current idc is the sum of two full-wave converter output
currents (idc1 and idc2) shown along with the output DC
voltage, Vdc.
Fig. 8 (a) shows the input and output current and
voltage waveforms of the full-wave 6-pulse AC-DC
Table 2 Comparison of power quality parameters of the load fed from different AC-DC converters at various loads
Sr. Topo- % %THD AC % THD Distortion Displace- Power DC Load Ripple
No. logy Load of VA Mains of IA, Factor ment Factor Voltage Current Factor %
Current Factor (Vdc) Idc
IA (A) (kA)
20 2.664 163.3 25.26 0.9693 0.9893 0.9589 88.54 11.41 3.238
1 6-pulse
100 5.562 559.2 18.51 0.9877 0.9771 0.9591 62.24 40.13 1.596
20 1.629 130.1 10.01 0.9948 0.9922 0.9871 81.36 10.50 1.128
2 12-pulse
100 3.011 490.1 5.175 0.9983 0.9816 0.9799 62.09 40.03 2.032
20 0.713 109.8 3.785 0.9993 0.9978 0.9971 75.08 10.30 0.318
3 18-pulse
100 0.417 442.7 1.270 1.0000 0.9959 0.9959 62.28 40.15 0.800
AC-DC converter at full-load. The THD of the AC current waveforms of the proposed 18-pulse AC-DC converter at
at full-load is observed to be 5.175%. The value of the light load. Fig. 12(b) shows the AC mains current
AC mains current THD is found to be less than that of the waveform iA and its harmonic spectrum. The harmonic
6-pulse AC-DC converter. spectrum clearly shows that the 17th and 19th are the
Fig. 12(a) shows the input AC phase voltage VA, input dominant harmonics and the THD of the AC mains current
AC current iA, output DC voltage Vdc, and load current idc (THDi) is 3.785% at light-load. Fig. 13 shows the
performance of the 18-pulse AC-DC converter at full-load.
The THD of the AC current at full-load is observed to be
1.27%. The value of the AC mains current THD is found
to be lower than that of the 6-pulse and 12-pulse converter
input currents and meets IEEE-519 Standard requirements.
The improvement in power quality indices such as total
harmonic distortion of the supply current (THDi), total
harmonic distortion of the supply voltage (THDv), distortion
factor (DF), and power factor (PF) at different loads can be
seen in Table 2. It can be seen that the THD of the input AC
current of the proposed 18-pulse full-wave AC-DC converter
system is around 5% at varying loads and its waveform is
close to sinusoidal. The power factor is observed to be of the
(a) Input and output voltage and current waveform
order 0.99 at varying loads in the proposed 18-pulse AC-DC
converter as given in Table 2. Moreover, Table 2 reveals that
the voltage distortion at the point of common coupling (PCC)
is negligible as THDv remains less than 1%. Further, the
input current has been reduced by about 20% in the
proposed configuration compared to the 6-pulse Full-wave
AC-DC converter. The mathematical analysis (section
2.2) shows that the rating of the transformer is 162.6%
which is of the order of other full-wave AC-DC converter
transformers but the power quality at its input is well within
the IEEE-519 Standard limits.
(b) Input current waveform and its harmonic spectrum
(a) Input and output voltage and current waveform (b) Input current waveform and its harmonic spectrum
Fig. 10 Twelve-pulse full-wave AC-DC converter at light-load
(a) Input and output voltage and current waveform (b) Input current waveform and its harmonic spectrum
Fig. 11 Twelve-pulse full-wave AC-DC converter at full-load
(a) Input and output voltage and current waveform (b) Input current waveform and its harmonic spectrum
Fig. 13 Eighteen-pulse full-wave AC-DC converter at full-load
6. Conclusions
input current is observed to be much less than 8% at [7] E.P. Wiechmann, R. P. Burgos and J. Holtz, “Sequential
varying loads meeting the IEEE-519 standard requirement. Connection and Phase Control of a High-Current Rectifier
The output voltage ripple is reduced to the order of less Optimized for Copper Electrowinning Applications”, IEEE
Trans. on Ind. Elect., Vol.47, No. 4, pp.734-743, 2000.
than 0.4% and the input power factor is improved at
[8] G. Oliver, G. E. April, E. Ngandui and C. Guimaraes,
varying loads thereby improving efficiency of the system.
“Novel Transformer Connection to Improve Current
Test results have validated the model and design of the Sharing in High-Current DC Rectifiers”, IEEE Trans. on
proposed 18-pulse AC-DC converter system. Ind. Appl., Vol. 31, No. 1, pp. 127-133, Jan./Feb. 1995.
[9] Shota Miyairi, Shoji Iida, Kiyoshi Nakata and Shigeo
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120 Journal of Power Electronics, Vol. 8, No. 2, April 2008