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http://dx.doi.org/10.6113/JPE.2012.12.3.387
JPE 12-3-2
Abstract
It is known that transformer based power supplies for ozone generators have low efficiency, high cost and exhibits a limited
frequency range of operation. To overcome these disadvantages, this paper proposes a high frequency ozone generator with the
absence of a transformer. The voltage step-up is achieved only by utilizing the resonant tank. This is made possible by a novel
combination of ozone chamber materials that allow ozone to be generated at only 1.5 ̶ 3.5 kVp-p. The input to the resonant tank is
driven by a PWM full bridge resonant inverter. Furthermore, zero-current zero-voltage switching (ZCZVS) operation is achieved by
employing a duty factor of 25% between the switches of the full bridge. The advantages of the proposed system include high
efficiency, low cost and the ability to control ozone production by varying the input voltage to the inverter. The prototype is verified
by both simulation and experimental results.
Key words: Full bridge inverter, High voltage transformer, Ozone chamber, Ozone generation, Resonant tank, Zero-current
switching (ZCS), Zero-voltage switching (ZVS)
Vmax
Rg (2)
Fig. 3. Ozone chamber configuration. Qc (vch 0)
where:
C. Ozone Chamber
The ozone chamber basically consists of two electrodes
separated by a dielectric material. It behaves mainly like Qc CmVmax (3)
capacitive load [4]. The chamber used in this work is shown in
Fig. 2. It consists of two aluminum mesh electrodes (outer side The values of Cm and Vmax can be obtained from V-Q
covered with copper tape) having a 120 mm length and a 70
mm width. One electrode is covered with muscovite mica Lissajous figure. For the chamber shown in Fig. 2, the
having a 0.1 mm thickness. The discharge gap between experimental results gives C g = 0.242 nF and Rg = 225 kΩ,
electrodes is 1mm [24]. at a frequency of 30 kHz.
In [28], a high frequency model of the ozone chamber is
presented by a parallel combination of Cg and Rg . The
III. ANALYSIS OF THE RESONANT TANK AND
complete model for the proposed ozone chamber is shown in OZONE CHAMBER CIRCUIT
Fig. 3. This simplified model is a linear one, in which Cg A circuit diagram of the resonant tank and the equivalent
circuit of the ozone chamber is shown in Fig. 5. The transfer
and Rg are very easy to estimate. To obtain the values of C g
function and the input impedance of this circuit is given by (4)
and Rg , voltage charge (V-Q) and voltage-current (V-I) and (8), respectively [29]-[31].
Lissajous figures are used.
Vo ( j ) 1
Av (4)
Vin ( j ) 2 2
2
The experimental setup to determine the chamber
1
parameters is shown in Fig. 4. The chamber capacitance Cg p p Q p
is calculated using:
Rg
Qp p Ct Rg (6)
p Ls
where:
The plot of (4) is shown in Fig. 6. It indicates that a large The operating waveforms of the full bridge inverter are
voltage gain can be achieved near p and that the value shown in Fig. 7. The equivalent circuits for each of the
operating modes are shown in Fig. 8. An adequate duty factor
of Qp is high at this point. For Q p 1 , and p , (4) is employed between the switches operation so that the reactive
energy stored in the snubber capacitors and intrinsic capacitors
becomes Av Q p and (8) becomes, Q p Z in
2
Rg . This
of the switches can be handled without a loss of efficiency. In
shows that voltage gain is load dependent and is directly order to achieve ZCZVS operation, a switching frequency must
proportional to the load resistance near the resonance. be selected that is greater than ωr. The circuit operation can be
The resonant frequency of the circuit can be found by taking divided into six modes as follows.
the derivative of (4) with respect to and substituting Mode 1 (t0 ̶ t1): During this mode M1 and M3 turn ON and the
d d Av 0 and r : DC power supply provides energy to the load. This mode is
called the rectifying mode. The current flows from the supply
to the load via switches M1 and M3 and the voltage VAB is +VCC.
1 The voltages across M1, M3, C1, C3, D1 and D3 are zero, and the
r p 1 (9) voltages across M2, M4, C2, C4, D2 and D4 are +VCC. The
2Q p2
current only flows through M1 and M3 and is given by:
Qp
Avm (10)
I M 1 I M 3 I out I in I p sin t (12)
1
1
4Q p2
where IP is the peak value of the current through switches M1
and M3.
where r is the resonant frequency and Avm is the Mode 2 (t1 ̶ t2): During this mode all of the switches are OFF.
The load current is diverted from M1 and M3 to charge C1 and
maximum voltage gain at this frequency. For Q p 1 , (10)
C3 from 0 to VCC and is given by:
becomes:
Ip
Avm Q p (11) I C1 I C 3 sin t (13)
2
Design and Development of a High-Voltage Transformer-less Power Supply for ... 391
Ip
IC 2 IC 4 sin t (16)
2
Ip
I C1 I C 3 sin t (17)
2
2 2
I M 2 I M 4 I out I in I p sin t (15) Vin , rms VCC (20)
392 Journal of Power Electronics, Vol. 12, No. 3, May 2012
Fig. 8. Overall operating modes of the full bridge inverter under ZCZVS operation.
Substituting the values of Vout from (18) and Vin,rms from (20) The resonant inductance and capacitance can be determined
yields: by combining (6) and (22) so that:
Pavg Rg 2 2VCC Rg
Avm (21) Ls (23)
2 2VCC p Pavg
Pavg
From (11), by substituting the values of Avm into (21) results Cp Cg (24)
in: 2 2 pVCC Rg
Pavg Rg The input current Iin can be derived by equating the average
Qp (22) product of the current and voltage with the average load power,
2 2VCC resulting in:
Design and Development of a High-Voltage Transformer-less Power Supply for ... 393
T
2
2 2 2
Pavg
T 0
Vin (t )iin (t )dt V I
CC in ,rms
(25)
Pavg
I in ,rms I L ,rms (26)
2 2VCC
B. Snubber Design
The dead time between the switches must be equal to charge Fig. 9. The circuit diagram of control circuit.
the output capacitance of each leg of the inverter [32].
2Q 2CVCC (27)
s Fig. 10. Design for the resonant Inductor.
B. Resonant Inductor
where Ip is the maximum value of switch current. Solving (27)
The desired value of LS, obtained from (23) is 35.78 mH.
and (28) gives the value of the snubber capacitor.
The inductor maximum voltage is 3.5 kVp at the resonance
frequency. The rms current IL, rms from (26) is 0.35A. The
I p (1 cos ) resonant inductor is implemented by placing isolation
C (29)
2sVCC between two layers of the turns as shown in Fig. 10.
The LS is designed by the area product (AP), approach. The
formula for AP, [33] is given by (30) as:
VI. IMPLEMENTATION
The design procedure is verified by implementing a 2 Energy 104
prototype power supply for an ozone chamber. The ratings are Ap (30)
m JK u
as follows: input voltage: 50 V, input power: 10 W and
2
switching frequency: 30 kHz. LI pk
Energy (31)
A. Control Circuit 2
A circuit diagram of the control circuit is shown in Fig. 9.
It provides the gate drive signals for the IRFP460 MOSFETs where Bm is the operating flux density, J is the current density,
M1–M4 in Fig. 1. The gate drive signals are generated by Ku is the window utilization factor and Ipk is the peak current
regulating the pulse width modulator (PWM) IC LM3524D. of the inductor.
The frequency of the drive signal can be calculated by the According to the design an ETD54 3C90 ferrite core is
voltage controlled oscillator (VCO), which can be determined used to build the resonant inductor.
by the values of R and C connected at the pins Rt and Ct. The
C. Resonant Capacitor
outputs of the LM3524D are two NPN transistors, driven 1800
The desired value of CP, obtained from (24), is 543 pF.
out of phase. Each output of the PWM IC is used to drive two
Since the voltage across the resonant capacitor is 3.5 kVp, it is
inputs of the SN7407 buffer. The duty cycle of the outputs can
implemented by a series-parallel connection of
be varied by the voltage applied at the COMP pin of the PWM
medium-voltage capacitors. Four film polypropylene
IC.
capacitors of 1500 pF nominal capacitance and 700 Vrms are
The outputs of the buffers are used to drive the four
connected in series, which results an equivalent capacitance
HCPL-3120 opto-couplers. The outputs of the opto-couplers
of 375 pF. Six film polypropylene capacitors of 1000 pF
394 Journal of Power Electronics, Vol. 12, No. 3, May 2012
(a) Simulation.
(a) Simulation.
(b) Experimental.
Fig. 11. Input voltage and current waveforms of the resonant (b) Experimental.
tank (a) Simulation (b) Experimental.
Fig. 12. Top: Switching Signal for M1 and M3, Middle:
Switching signal for M2 and M4, Bottom: Inverter current, (a)
Simulation (b) Experimental.
nominal capacitance and 700 Vrms are connected in series,
which results an equivalent capacitance of 166 pF. The
resulting 375 pF and 166 pF capacitances are connected in
parallel to make an equivalent capacitance of 541 pF. input of the resonant tank. The operation is performed above
the resonance and the resonant tank represents an inductive
VII. SIMULATION AND EXPERIMENTAL RESULTS load to the inverter. As can be seen, the current lags the
voltage.
A prototype has been implemented and tested using the Fig. 12 shows the switching signals of the MOSFETs
above calculated values. Furthermore, the circuit is simulated together with the output current of the inverter. As can be
in MATLAB/SIMULINK. The resonant frequency is set to seen, the power switches turn on at zero current. As a result,
29.5 kHz. The voltage gain at the resonant frequency is 45. the turn on switching loss is zero. However, there are turn off
The switching frequency of the inverter is selected at 30 kHz, losses in the power switches. As explained in section IV, in
which is above the resonant frequency. This is done to mode 2, at 25% of the duty cycle, the switches M1 and M3
achieve the ZCZVS condition. The switching frequency is turn off. This starts the commutation process. The inverter
kept constant, while the voltage of the ozone chamber is output current discharges C2 and C3 while charging C1 and C4.
varied by varying the input voltage. The input voltage of the When the voltages across C1 and C4 reach VCC, the voltages
inverter is varied between 25V and 35V. across C2 and C3 becomes zero.
Fig. 11 illustrates the current and voltage waveforms at the
Design and Development of a High-Voltage Transformer-less Power Supply for ... 395
(a) Simulation.
(b) Experimental.
(b) Experimental.
(c) Simulation.
Fig. 13. Switching signals of the MOSFETs and voltage
across MSFETs, (a) Simulation (b) Experimental.
(d) Experimental.
Fig. 14. Voltage and current waveforms of ozone chamber at
various inverter input voltages. At inverter voltage of (a)
Simulation at 25V. (b) Experimental at 25V (c) Simulation at
(a) Simulation.
35V and (d) Experimental at 35V.
396 Journal of Power Electronics, Vol. 12, No. 3, May 2012
Fig. 15. Variation of ozone quantity with input voltage of Fig. 16. Inverter input voltage versus the efficiency of the
inverter. inverter.
simulation and experimental results are found to be in close [15] P. Hothongkham and V. Kinnares, “High-voltage
agreement with the theoretical predictions. high-frequency power supply using a phase-shifted PWM
full bridge inverter fed ozone generator with constant
applied electrode voltage,” in Proc. IPEC, pp. 1560-1567,
ACKNOWLEDGMENT 2010.
[16] P. Hothongkham and V. Kinnares, “Measurement of an
ozone generator using a phase-shifted PWM full bridge
The authors would like to thank the Universiti Teknologi inverter,” in Proc. IPEC, pp. 1552-1559, 2010.
Malaysia for providing the facilities and research grant to [17] V. Kinnares and P. Hothongkham, “Circuit analysis and
conduct this research through vot. No 79411.” modeling of a phase-shifted pulsewidth modulation
full-bridge-inverter-fed ozone generator with constant
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