HVHF Transformer
HVHF Transformer
1, JANUARY 2001 89
I. INTRODUCTION Fig. 1. Conventional high voltage DC power supply. TH1, TH2: Thyristor set.
T1: High voltage, low frequency transformer. D1, D2, D3, D4: High voltage
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FOTHERGILL et al.: A NOVEL PROTOTYPE DESIGN FOR A TRANSFORMER FOR HIGH VOLTAGE, HIGH FREQUENCY, HIGH POWER USE 91
B. Insulation Materials
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Fig. 7. Electrostatic electric field analysis around slots in the high voltage
bobbin. The hashed regions corresponding to the windings which are assumed
Fig. 5. Side-view of high-voltage bobbin showing stress-relief rings and slots to be equipotential regions. The highest fields of 5 kV.mm can be seen to
for layered windings. occur on the corners of the slots.
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FOTHERGILL et al.: A NOVEL PROTOTYPE DESIGN FOR A TRANSFORMER FOR HIGH VOLTAGE, HIGH FREQUENCY, HIGH POWER USE 93
Fig. 9. Primary voltage (lower trace) and current (upper trace) for 38 kV
output.
Fig. 8. Measured current–voltage characteristic under electrostatic there is a current path through their flywheel protection diodes.
precipitator load. The current during this period is otherwise uncontrolled and
the small current oscillation during the dead time probably
corresponds to a resonance of the magnetizing inductance with
was difficult to obtain accurate results because of the unsteady the parasitic capacitance.
current drawn. It was difficult to estimate the efficiency of the transformer
Fig. 8 shows the measured current-voltage characteristics accurately because of the measurement uncertainty in the
of the electrostatic precipitator load; the line is an exponential continuously fluctuating secondary current and unfortunately
curve drawn to assist the eye. The current increased rapidly the experimental arrangement precluded measurement of the
above a corona inception voltage of approximately 30 kV. instantaneous secondary current. All our estimates lead us to
The circled groups of measurements at approximately 0.2 A believe that the efficiency of the transformer with rectifier was
( kV) and 0.4 A ( kV) were almost certainly made better than 97%. The total rectifier voltage drop was 200 V
as the supply was recovering from a spark in the precipitator. which, at 0.4 A, would give an 80 W power loss and contribute
The voltage is increasing at this point but little corona current % to the overall power lost. The best indication of power
is being produced. By extrapolation of the exponential, it may loss was the temperature rise of the transformer core, which
be estimated that the transient arcing current was several amps was measured using a thermistor. The temperature rose from
at the higher voltages. The dotted exponential curve shows the C to C, a rise of C, when the output was
average “steady-state” characteristics of the precipitator. 45 kV, 0.4 A, a power of 18 kW. The design calculations,
Conventional transformer-rectifier sets have ripples that are Appendix A, suggest that with a loss of 510 W, a temperature
typically 50% of the mean voltage [14]. Arcing occurs if the rise of C would be found for a core surface area of 533 cm .
peak of the voltage ripple exceeds a critical value and so for The actual exposed surface area was approximately 800 cm .
much of the cycle, when the voltage is much less than this crit- An estimate of the actual power lost is therefore
ical value, little corona current is produced. Typically the mean
current is much less than half that produced at the peak. Further-
more the ripple produces a considerable capacitive displacement
C cm
current which increases the size of the secondary transformer W W
windings. In this high frequency supply, very little ripple was C cm
observed. At 30 kV the ripple was V, at 44 kV it was
V; i.e. it was much less than 1% under all conditions. It For an output power of 18 kW this corresponds to an efficiency
is therefore possible for the supply to produce more than twice of 98.5%. The overall efficiency of the power supply was
as much current without arcing occurring. estimated to be % which compares very favorably with
Fig. 9 shows the primary current and voltage waveforms for conventional 50 Hz transformer–rectifier sets with efficiencies
an output of 38 kV. As the primary voltage is provided by a of only %.
phase-controlled H-bridge, there is a dead time between both
positive and negative cycles when the duty cycle is less than
100%. By considering the voltage waveform in Fig. 9 it can IV. CONCLUSION
be seen that the period is approximately 50 s corresponding
to a switching frequency of 20 kHz. The duty cycle was set A highly efficient high-voltage high-frequency transformer
to 40% with the dead times equal to 10 s and the positive has been designed, built and field tested. The transformer
and negative on times being 15 s. The primary voltage was formed part of a switched-mode power supply for electrostatic
V. During the positive (negative) on times the current precipitators. The design, which is still at a prototype stage, was
increased (decreased) reasonably linearly, due to the magne- found to be much more efficient and smaller than conventional
tizing inductance, to a value of approximately A. 50/60 Hz transformer rectifier sets. The unit will now be
During the dead times all four H-bridge transistors are off but developed for manufacture.
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APPENDIX
MAGNETIC AND THERMAL DESIGN USING MCLYMAN DESIGN METHOD
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ACKNOWLEDGMENT REFERENCES
[1] P. J. Devine, “The requirements of a high voltage DC power supply,”
Leicester University Engineering Department, 1995.
The authors would like to thank R.I. Deakin, M. Selby (NP), [2] G. Liberati, “High voltage, high power switched mode power supply for
ion production,” ENEL, CRTN.
D.A. Rose (DTI), K.R. Parker and D.F. Warne for their consid- [3] M. A. Perez, “A new topology for high voltage, high frequency trans-
erable technical assistance and support throughout the project. formers,” IEEE, 0-7803-2482-X/95, 1995.
They would also like to thank A. Smith and A. Joseph for their [4] H. Takano, “Feasible characteristic evaluations of resonant inverter
linked DC-Dc power converter using high voltage transformer parasitic
cooperation and assistance with the field trial at Didcot A power components,” in Power Electronics and Variable Speed Drives: IEE,
station. Sept. 23–25, 1996, pp. 525–533.
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98 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 16, NO. 1, JANUARY 2001
[5] W. T. McLyman, Transformer and Inductor Design Handbook. New Philip Devine was born in 1971. He graduated from
York, NY: Dekker, 1978. the University of Leicester in 1994 and is currently
[6] S. M. Rowland and I. V. Nichols, “Effects of dry-band arc current on studying for a Ph.D. by part-time study. Prior to his
ageing of self-supporting dielectric cables in high fields,” IEE Proc., degree he worked for Heenan Drives Ltd. He was em-
Science, Measurement and Technology, vol. 143, no. 1, pp. 10–14, Jan. ployed as a Research Assistance on the project de-
1996. scribed in this paper and is now a Teaching Company
[7] J. C. Fothergill and L. A. Dissado, Eds., Space Charge in Solid Di- Associate. His main area of interest is in high voltage
electrics: The Dielectrics Society, 1998, pp. 259–272. power electronics.
[8] L. A. Dissado, G. Mazzanti, and G. C. Montanari, “The role of trapped
space charges in the electrical aging of insulating materials,” IEEE
Trans. DEIS, vol. 4, no. 5, pp. 496–506, Oct. 1997.
[9] J.-P. Crine, “A molecular model to evaluate the impact of aging on space
charges in polymer dielectrics,” IEEE Trans. DEIS, vol. 4, no. 5, pp.
487–495, Oct. 1997.
[10] P. Connor, J. P. Jones, J. P. Llewellyn, and T. J. Lewis, “Mechanical
origin for electrical ageing and breakdown in polymeric insulation,” in Paul Lefley was born in Ipswich, UK in 1964.
Proceedings of the 1998 IEEE 6th International Conference on Con- He graduated from the University of Nottingham
duction and Breakdown in Solid Dielectrics, Conf. code 49 244, pp. in 1985, and was awarded a Ph.D. from the same
434–438. institution in 1989. He worked for Mobicom Ltd.
[11] J. W. Williams, “Navy/industry ‘NAVMAT’ high voltage guide- from 1988–89. In 1989 he returned to Nottingham
lines—An overview,” in 1995 High Voltage Workshop, USA: University where he was awarded a three year
University of Utah. Post-Doctoral Fellowship. In 1992, he moved to
[12] Conti-Elektro-Berichte, July/Sept. 1966, p. 189. the University of Leicester where he took up the
[13] H. A. Pohl, Dielectrophoresis. Cambridge: Cambridge University post of lecturer. His main area of interest is power
Press, 1978. electronics and machines. Whilst at Leicester
[14] K. R. Parker, Ed., Applied Electrostatic Precipitation: Chapman and he has been chairman and treasurer of the IEE
Hall, 1997. East Midlands Power Division, and chairman of the 34th University Power
Engineering Conference.
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