High voltage switch for compact bidirectional dc-dc converter driving dielectric electroactive polymer actuators

Driving DEAs requires time-varying high voltage power supplies, up to 18kV for 200um polymer layers. HV amplifiers are commonly used but bulky and expensive. Designing embedded actuators requires compact and efficient powersupplies. Furthermore, only a little part of the electrical energy delivered to the DEA is converted to mechanical energy. The major part is stored in the capacitance of the actuator and needs to be recollected to maximise the system's efficiency. Low cost integrated bidirectional DC-DC converters (ex. Flyback) have been proven reliable to drive DEAs at voltages up to 2,5kV. To design a reversible converter with an output voltage up to 18kV, a high voltage switch is needed. Yet, the maximum breakdown voltage for a MOSFET with current ratings inferior to 200mA is 4,5kV. Our simulation and experimental work demonstrate a reliable driving circuit for triggering two series connected MOSFETs. A wide voltage switching range is achieved (0 to 8kV) with a 200mA current rating. Using the Transformer Gate Driver topology, galvanic insulation and synchronisation of each gate driver is ensured. To gain an equal distribution of the bus voltage over the MOSFETs, mastering the parasitic capacitances is mandatory. A design method has been developed to compensate these parasites and ensure the reliability of the device. The architecture of the high voltage switch is N-scalable and a switching range from 0 to 18kV could be achieved when stacking five MOSFETs in series.

Control Strategy for the Discharge Phase of an Ultra-High Voltage (>7kV) Bi-Directional Flyback Converter Driving Capacitive Actuators

Alexis Boegli, Raphaël Johannes Charles Mottet, Yves Perriard

Dielectric Elastomer Actuators (DEAs) require ultra high voltages in the order of several kilo volts to operate. To supply such voltages, a DC-DC flyback converter topology was selected. One of the main advantage of using such a structure is the possibility to modify it to work bidirectionally. Meaning that electrical energy can not only flow from the power supply to the actuator, but also from the actuator back to the power supply. This characteristic is of significant importance because of the need to recuperate the electrical energy stored in DEAs to improve the overall efficiency of the system instead of dissipating it as heat. Indeed, due to their capacitive nature, DEAs can store an important amount of energy when fully deformed which needs to be removed to bring the actuator back to its original shape. This paper focuses on the control aspect to remove the stored energy when using a bi-directional flyback converter capable to supply a voltage of up to 7 kV to the load from a 12V power supply. After a brief presentation of the working principle of the discharge procedure, the implemented control strategy is detailed in depth with the presentation of the hardware used and the control algorithm put in place. Experimental results then show that the control strategy works well with an output voltage of up to 7 kV but is nonetheless close to its limits because of increasingly small measuring time spans going down to several micro seconds.

2020

Ultra-High-Voltage (7-kV) Bidirectional Flyback Converter Used to Drive Capacitive Actuators

Morgan Almanza, Alexis Boegli, Raphaël Johannes Charles Mottet, Yves Perriard, Lucas Pniak

Dielectric elastomer actuators (DEAs) have extremely advantageous characteristics such as lightness, compactness, flexibility, and large displacements. However, in order to operate, they can require voltages in the order of several thousands of volts. Thus, to unleash the full potential of DEAs, it becomes essential to be able to generate and manipulate such voltages with an electronics as compact and efficient as possible. While previous works showed that it was possible to implement a system capable of supplying voltages of up to 2.5 kV and recovering part of the energy stored in DEAs (due to their capacitive nature), no work managed to go over that threshold for two main reasons: first, due to the absence of switches capable of withstanding more than 4.5 kV, and, second, due to parasitic capacitances of the flyback's coupled inductor, which steal an increasingly large part of the energy destined for the load when the output voltage is higher. This article, therefore, proposes a global design, where the factors limiting the increase in the output voltage have been mastered. Through a careful design of the coupled inductor combined with the use of MOSFETs put in series, thanks to the pulsed transformer gate drive topology to handle the high voltages, this work goes beyond the current state of the art. Indeed, here, we present various strategies undertaken, which led to the manufacture of a bidirectional flyback converter capable of amplifying an input voltage of 12 V to more than 7 kV across a capacitive load and recuperating parts of the energy stored. A preliminary study of the efficiency shows an approximate 58% efficiency during the charge phase from 0 V to 7 kV and a 54% efficiency during the discharge phase.

IEEE-INST ELECTRICAL ELECTRONICS ENGINEERS INC2021

A contribution to energy saving in induction motors

Electric motors consume over half of the electrical energy produced by power stations, almost the three-quarters of the electrical consumption in industry and almost the half of commercial electrical consumption in developed countries. Motors are by far the most important type of electric charges, and so constitute the main targets to achieve energy saving. Owing to their simple and robust construction, the asynchronous motors and especially those of squirrel-cage types, represent about 90-95% of the electrical energy consumption of electric motors, which is equivalent to about 53% of total electrical energy consumption. They are widely used as electrical drives in industrial, commercial, public service, traction and domestic applications. Owing to the importance of induction motors, this thesis is aimed at contributing to energy saving efforts, more specifically in the field of low power induction motors. A contribution is kept in perspective by taking into consideration the energy saving potential during the motor design stage as well as during its operation. Every effort to save energy in motor application can be made by always attempting to use energy only as much as what needed during its operation. The best way is to exploit the saving potential during motor design, while at the same time taking into account its intended application. It can be achieved either through the improvement of motor design or through the reduction of its input electrical energy when the motor has already been built. These two efforts are studied, elaborated and worked out thoroughly in this thesis. To attain this objective, a synthesis has been started with the description of how to model an induction motor. To obtain a better model, an improvement is proposed by using the Schwarz-Christoffel mapping to calculate the slot leakage inductance in induction motor. With such method, slot-leakage inductance can be determined more precisely, resulting in more accurate prediction of motor characteristics. It is based on the stored magnetic energy calculation using two-directional field distribution in the slot. The air gap influence can be observed easily, so that a reasonable slot leakage definition can be adopted. Unlike the conventional method, which is only suitable for rectangular slots (otherwise empirical corrections are required), the proposed general slot form can be extended to any desired polygonal slot form. Consideration of saturation is also indispensable because ignoring it could result in inaccuracy in motor performance prediction. Considering the saturation is essential owing to its important role in self-excitation phenomenon to establish voltage build-up in induction generator. However, the self-excitation phenomenon is undesirable in certain group of capacitor motors as it may hinder the switching-off process and mechanical braking at a desired moment. The undesirable switching-off failure condition is to be avoided by properly designing the capacitor motor. Like in this capacitor motor special application, where a proper design is useful from the point of view of operation safety, designing properly a motor is also very important in energy saving efforts. Motor design and optimization to minimize losses as well as to make possible wide speed-range motor operation are some of the efforts. However, when induction motor has already been built, saving energy is only possible by managing its supplying electrical energy. Various strategies are possible and a particular emphasis on the use of triac to reduce motor input voltage is presented. Besides, a brief economic saving evaluation is given to draw attention to the energy saving potential.

EPFL2005

A contribution to energy saving in induction motors

EPFL2005