High-Efficiency Pure Sine Wave Inverter

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keyboard_arrow_downTitleAbstractKey TakeawaysIntroductionBackgroundDesign Specifications and ProcedureHigh-Frequency Transformer DesignSnubber DesignInverter Low Pass Filter DesignImplementation of DesignResultsInverter Testing & ResultsReferencesFAQsAll TopicsEngineeringElectrical Engineeringdownload

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Abstract

The purpose of the project was to design a high-power inverter to rival that of use in the market in terms of cost and efficiency. The efficiency was the key driving force in the project. The inverter consists of 3 stages: the boost stage, inverter stage, and filter/load stage. The boost stage consists of an isolated DC-DC converter which will take a low DC input supply and boost it to a regulated high DC output. (controlled by PWM signals). The inverter takes the high DC bus from the boost stage and inverts it to a chopped AC, which is filtered to output a pure sine wave. Load testing and efficiency calculations are done on the inverter.

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Key takeaways

AI

1. The project aims to design a cost-effective, high-efficiency pure sine wave inverter for market competitiveness.
2. The inverter consists of three stages: boost, inverter, and filter/load, optimizing performance and output quality.
3. Efficiency peaks at 87% under a 340Ω load, with maximum output power of 90.34 W at 79.15% efficiency at 75Ω.
4. The PWM duty cycle is set at 45% for optimal switch operation and minimal harmonic distortion.
5. Testing reveals significant third harmonic content, necessitating a higher-order low-pass filter for output refinement.

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References (35)

1. List of Equations Equation 1: Input to output voltage transfer function ................................... Equation 2: Switching period ............................................................................. Equation 3: Maximum duty cycle ..................................................................... Equation 4: Maximum duty cycle for each phase ........................................ Equation 5: Input power ..................................................................................... Equation 6: Max. average input current ......................................................... Equation 7: Max. Equivalent flat topped input current ................................. Equation 8: Max. input RMS current ................................................................. Equation 9: Max. MOSFET RMS current ............................................................. Equation 10: Min. MOSFET breakdown voltage .............................................. Equation 11: Transformer turns ratio.................................................................. Equation 12: Min. duty cycle ............................................................................. Equation 13: Nominal duty cycle ...................................................................... Equation 14: Average output current .............................................................. Equation 15: Secondary max. RMS current ..................................................... Equation 16: Rectifier diode voltage................................................................ Equation 17: Min. output filter inductor ............................................................ Equation 18: Output filter inductor ................................................................... Equation 19: Min. output current ...................................................................... Equation 20: Max. output ripple ........................................................................ Equation 21: Output filter capacitor value ..................................................... Equation 22: Equivalent Series Resistance ....................................................... Equation 23: RMS capacitor current ................................................................ Equation 24: Ripple input voltage .................................................................... Equation 25: Input capacitor............................................................................. Equation 26: Apparent power ........................................................................... Equation 27: Ke parameter ................................................................................ Equation 28: Core geometry parameter ......................................................... Equation 29: Kg relation to core ....................................................................... Equation 30: Core window area ....................................................................... Equation 31: Primary turns calculation ............................................................. Equation 32: Bmax check .................................................................................. Equation 33: Primary inductance value .......................................................... Equation 34: Secondary turns calculation ...................................................... Equation 35: Skin depth ...................................................................................... Equation 36: Wire diameter ............................................................................... Equation 37: Conductor section ....................................................................... Equation 38: Wire diameter for AWG21 ........................................................... Equation 39: Wire area for AWG21 ................................................................... Equation 40: Wire resistance for AWG21 ......................................................... Equation 41: Number of primary wires ............................................................. Equation 42: Total area of primary side ........................................................... Equation 43: Primary resistance ........................................................................ Equation 44: Primary resistance value ............................................................. Equation 45: Total area of secondary side ...................................................... Equation 46: Number of secondary wires ........................................................ Equation 47: Secondary resistance .................................................................. Equation 48: Secondary resistance value ....................................................... Equation 49: Total copper losses ....................................................................... Equation 50: Transformer regulation ................................................................. Equation 51: Inductor Peak current value ....................................................... Equation 52: LI^2 product .................................................................................. Equation 53: Minimum nominal inductance ................................................... Equation 54: Number of turns ............................................................................ Equation 55: DC bias ........................................................................................... Equation 56: Adjusted number of turns ............................................................ Equation 57: Circumference of inner core ...................................................... Equation 58: Width of AWG21 ........................................................................... Equation 59: number of turns/layer .................................................................. Equation 60: Total layers ..................................................................................... Equation 61: Stored energy in a capacitor ..................................................... Equation 62: Estimate of power dissipation ..................................................... Equation 63: Capacitor in snubber .................................................................. Equation 64: Dissipated power .......................................................................... Equation 65: Power dissipated in Rs ................................................................. Equation 66: Conduction loss in MOSFET ......................................................... Equation 67: MOSFET gate loss .......................................................................... Equation 68: Switching losses in MOSFET .......................................................... Equation 69: Conduction losses in diode ........................................................ Equation 70: Switching losses in diode ............................................................. Equation 71: Filter cut-off frequency ................................................................ Equation 72: Capacitive reactance ................................................................ Equation 73: Filter capacitor value ................................................................... Equation 74: Resonant frequency of filter ....................................................... Equation 75: Actual filter capacitor value ...................................................... Equation 76: Measured turns ratio .................................................................... Equation 77: Measured total inductance ....................................................... Equation 78: Leakage inductance value ........................................................ Equation 79: Input compare register ................................................................ Equation 80: Sample number ............................................................................ Equation 81: AC voltage reading ..................................................................... Equation 82: Sample voltage calculation ...................................................... Equation 83: AC voltage reading at the LCD................................................. Bibliography
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FAQs

AI

What are the efficiency levels achieved in loading scenarios?add

The inverter achieves a maximum efficiency of 87% at a 340Ω load, producing 90.34 W. However, at a full load of 75Ω, efficiency drops to 79.15% with 462.50 Watts output.

How does the push-pull converter topology benefit inverter applications?add

The push-pull topology allows operation at lower input voltages and supports higher power applications effectively. Its design enables efficient power conversion without requiring isolated drivers, enhancing overall system reliability.

What role does PWM play in minimizing harmonic distortion?add

Pulse Width Modulation (PWM) significantly reduces total harmonic distortion in load current. By controlling the duty cycle, PWM ensures efficient switching, producing a waveform closer to the desired pure sine wave output.

What are the transformer design specifications for high-frequency applications?add

The project utilizes the E65/32/27 core with N27 ferrite, featuring a saturation flux density of 320 mT. This design enables fewer turns while achieving the required inductance, minimizing leakage inductance.

How are MOSFET characteristics leveraged for improved inverter performance?add

MOSFETs like the IRFP460 are chosen for their fast switching times, low on-resistance, and high power efficiency. Paralleling multiple MOSFETs reduces conduction losses, making them ideal for high-frequency operation in the inverter.

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