High Voltage AC-AC Converter
This project started with an interesting question: can we use a standard full-bridge inverter topology to convert AC to AC? More interestingly, could we convert a range of AC Mains to AC outputs of different frequencies and waveforms? Turns out the answer was yes! The implementation however, was filled with challenges and required some out-of-the-box design techniques….
PCB Design
Once the schematic concepts were simulated and captured, a multi-domain four-layer PCB was designed for fabrication. The design posed several unique challenges including high-voltage creepage and clearance constraints, floating ground planes, high-speed PWM signals, and multi-board stack up interfaces.
Liquid Cooling
High power switches need cooling, usually with a heatsink and possibly a fan. We worked with our mechanical engineers to create a liquid cooled design using aluminum extrusion, custom 3D printed tubing adapters, and TO-220 clips. The result was excellent thermal management with favorable packaging options for the clients application.
High Voltage
Switching high-voltage power lines requires a special subset of skills to manage noise, heat, and safety. Using a combination of simulation and low-voltage validation, designs like these can be brought to life with minimal iteration and rework. Component selection is another critical aspect of this type of work, requiring attention to data sheet detail for capacitors, inductors, switches, and drivers.
Data Analysis
At the end of the day, the output from a project like this is mostly data. Thermal measurements, efficiency analysis, high voltage differential signal waveforms… these items form the bridge between Research and the eventual Development of product.