New signal conditioning stage for HBBPFC

DESCRIPTION

Power factor correctors or PFCs are developed as a solution to power consumption problems due to their high power factor, protect systems against voltage fluctuations and high currents [1], [2].


The purpose of a PFC is that the input current follows the sinusoidal form of the line voltage, so that its unit power factor is obtained [1], [2].


The HBBPFC is a converter designed to obtain 400VDC output, powered from the mains and obtaining a power factor PF = 1 (see results here) [1], [2].


To carry out the control step a Texas Instruments DSP (TMDX28069USB or Piccolo F28069) is used [3], [4], [5], [6]. This development card is observed in detail below:


PICCOLO_opt.jpg

Figure 1: Piccolo F28069 [1]


The Piccolo F28069 is obsolete, for that reason, the conditioning stage must be redesigned.


OLD CONDITIONING STAGE


Over time, many PCBs have been made from the signal conditioning stage. The first PCB is shown below:


Coupling_galvanic_isolated_PCB_opt.jpg

Figure 2: signal conditioning stage first PCB.


This PCB has protection by galvanic isolated. The second version of that was a better design. As shown in the following figure:


Conditioning_opt.jpg

Figure 3: signal conditioning stage second PCB.


Nevertheless, both PCBs did not function well because the drastic reduction in all signals caused by the galvanic isolated protection was the main problem. For this reason, the conditioning signal was redesigned from a new control diagram.


Control_opt.jpg

Figure 4: control diagram applicated for a HBBPFC international project [1].


From that diagram another PCB is created without the galvanic isolated protection, avoiding the problem mentioned above. This printed circuit board is:


1.jpg

Figure 5: signal conditioning stage third PCB [1], [2].


Because the Piccolo™ F28069 is obsolete, the signal conditioning stage shall never use more, therefore, it's created a new version that consists in change the microcontroller for a FPGA with reference CY8CKIT-059 PSoC 5LP CY8C5888LTI_LP097. This development board has digital and analog devices incorporated reducing the number of external components and simplify the design with the same control diagram (shown in the figure 4). That PCB include the supply stage and is observed below:


NEW_PCB_opt.jpg

Figure 6: signal conditioning stage new PCB.


This PCB is perfectly assembled with the current HBBPFC power stage shown below:


HBBPFC_Photo_opt.jpg

Figure 7: HBBPFC power stage.


REFERENCES


[1] A. G. Rubiano-Muñoz. “módulo de interconexión entre una fuente para DBD y la red eléctrica”. Andy Rubiano™, pp. 1 - 110. May 2017.


[2] A. G. Rubiano-Muñoz. “HBBPFC design and implementation”. Andy Rubiano™,. Recuperated on september 9th of 2017, 2017. [Online]. Available: https://www.pcbway.com/project/sponsor/HBBPFC_design_and_implementation_project.html


[3] C2000™ MCU 1-Day Workshop, Texas Instruments, february 2012, workshop guide and lab manual.


[4] Piccolo Microcontrollers, Texas Instruments, mayo 2012, datasheet of Piccolo™ series, applicated to the microcontrollers TMS320F28069, TMS320F28068, TMS320F28067, TMS320F28066, TMS320F28065, TMS320F28064, TMS320F28063, TMS320F28062.


[5] TMS320x2806x Piccolo, Texas Instruments, december 2011, technical reference manual.


[6] Software Frameworks for C2000 Piccolo™ 32-Bit MCU Family, Texas Instruments.


Words to PCBWay


Thank you PCBWay and Anson Bao for manufacturing the PCBs and helping me. Excellent service.


Andy Rubiano 

Electronic engineer. All Rights reserved.

Twitter: @RubianoAndy.

Facebook: @RubianoAndy.

Instagram: @RubianoAndy.

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