Three-Phase Power Conversion in a Single Step

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1 Patent Pending Three-Phase Power Conversion in a Single Step 1-STEP Offers Active Power Factor Correction and Isolated, Regulated DC Output with Unparalleled Power Density 78 Boonton Avenue, P.O. Box 427, Montville, New Jersey USA P F

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3 Executive Summary OEMs seek continuous improvements in power conversion - particularly in military, shipboard and aerospace applications. Obtaining regulated and isolated power for electronic circuits is a complex and costly process involving multiple conversion steps. This process is commonly required for AC to DC conversion in high power applications, demanding close attention to performance requirements such as power factor and input current distortion, as well as size, weight, efficiency, reliability, and cost. To solve these challenges for the power conversion engineer, Marotta Controls has developed its new patent-pending 1-STEP AC-DC Conversion solution. 1-STEP uniquely achieves three-phase Active Power Factor Correction (APFC), output regulation and electrical isolation in a single conversion step. 1-STEP utilizes approximately half the component-count found in conventional solutions, inherently providing greater reliability via the simplicity of the 1-STEP topology. This report provides a brief technical overview of 1-STEP AC-DC Conversion, contrasting this new technology to existing conversion options. Marotta s 1-STEP AC-DC Conversion A B C Provides APFC Provides Low Harmonics Provides Regulation Provides Isolation Output Total Efficiency 93% Step 1 AC-DC Rectification Step 2 DC-DC Conversion Typical Systems A B C Provides PFC Provides Low Harmonics Bus Voltage Provides Regulation Output Total Efficiency Provides Isolation 90% Typical devices for converting a three-phase power input to a usable DC output generally require two steps: a rectification stage (and active power factor control for converting AC input to an intermediate DC voltage), followed by a DC-DC conversion stage for regulating and isolating the desired DC output voltage. Marotta s 1-STEP AC-DC Conversion Technology executes all stages in a single conversion step while providing unparalleled power density. 1

4 Three-Phase Power Conversion in a Single Step 1-STEP Offers Active Power Factor Correction and Isolated, Regulated DC Output with Unparalleled Power Density Today s advanced power electronics circuitry is enabling the replacement of mechanical, pneumatic and hydraulic systems in mission-critical settings. The resulting improvements in Size, Weight, Power and Cost (SWaP-C) are driving advancements in military platforms, shipboard systems and commercial aircraft. While power factor correction and low current distortion are key challenges in this process, existing conversion options such as auto transformer rectification units (ATRUs) and Vienna rectifiers can only solve these issues by accepting performance trade-offs that negatively impact SWaP-C. Groundbreaking because it achieves regulation, isolation and active power correction in a single step, 1-STEP technology not only simplifies complex circuitry, it creates a significant design advantage with reduced size and weight, low harmonics (<3%) and near unity power factor. 1-STEP works with input power frequencies of DC up to 1,000 Hz, making it capable of connecting to 50/60 Hz power systems. This provides an advantage for ground operations logistics by having the ability to connect to utility power without special ground equipment. To remove these limitations and improve performance of power electronics designs, Marotta Controls has developed 1-STEP. Electronic systems are replacing mechanical, hydraulic and pneumatic systems at an unprecedented rate, enabling the rapid growth of new all-electric technologies such as those found in military and commercial aircraft, satellites, surface ships, submarines, and even automobiles, railroads and unmanned systems. This global trend towards all-electronic systems is generating greater demands for efficiency in power conversion. 2

5 Why Choose 1-STEP? Devices for converting a three-phase power input to an adjustable DC output generally include two steps: a rectifier and power factor correction stage (for converting three-phase AC input into a DC voltage), followed by a DC-DC conversion stage (to regulate the DC output voltage). The DC-DC conversion stage may be capable of raising or lowering the DC voltage level, or both, depending on the particular features of a given device. 1-STEP represents a breakthrough in power electronics, meeting these needs with the same or better power efficiency than existing solutions, uniquely offering three-phase conversion in a single step. With 1-STEP, power electronics engineers are able to achieve high efficiency conversion performance with fewer components, minimizing cooling requirements and meeting the need for lighter, less costly systems. Design Advantages APFC Plus Output Regulation and Isolation in a Single Step Unparalleled Power Density < 3% Total Harmonic Distortion Simplified Rectifier / Converter Topology - no APFC stage Near Unity Power Factor Output Voltage Can be Stepped Up or Down Inherent Load Sharing Wild Frequency Input High Reliability High Efficiency Small CE filter Output Power from 1k to 150kW (1) (1) With multiple modules Shown left: a 3kW version of Marotta s new 1-STEP AC-DC Conversion Technology. 1-STEP AC-DC Conversion Technology Marotta s 1-STEP is a high efficiency, power factor corrected, three-phase AC-DC converter. Power factor correction, output regulation and isolation are handled in one step, providing higher conversion efficiency. The resulting lighter weight and reduced complexity afford higher reliability and lower lifecycle costs. Unity power factor is achieved through the entire load range without a separate PFC stage; output can be stepped up or down depending on the needs of the application. Load sharing occurs automatically with multiple 1-STEP converters. Care in the design of the input EMI filter preserves power factor performance under no- or low-load conditions. 3

6 Challenges of Three-Phase Power Conversion The goal of three-phase AC-DC power conversion is to provide isolated, regulated DC output, with very low current harmonics and near unity power factor at the input. Key challenges harmonics, power factor correction, electrical isolation and input current distortion consume engineering resources during the design process. The ideal result is high conversion efficiency and unparalleled power density. Power Factor Correction. Particularly in high power applications, AC-DC conversion circuitry needs to provide power factor correction (PFC). PFC prevents harmonic currents from distorting the supplied current waveform. As a result, both input voltage and current waveforms are kept in phase to maintain the near unity power factor of the three-phase power input. 1-STEP provides near unity power factor at both full and partial loads without a separate PFC process. Electrical Isolation. Electrical isolation may be necessary to protect circuits, equipment and operators from shocks and short circuits that may occur in the system. Isolation also separates load and power systems, which helps prevent ground loops and protects the load from abnormal power system events. In some applications, output voltage must be electrically isolated from the input, creating a very high resistance between the two. Marotta s 1-STEP power design enables galvanic isolation between output and input; if a short circuit occurs at the output, the function stops and the system is safe. Input Current Distortion. A fullwave rectifier is often used to convert three-phase AC to DC voltage; the device incorporates six diodes in a full bridge configuration. However, this topology allows just two of three phases to provide power at one instant, while the third phase is inactive. The resulting current discontinuity causes problems in realizing low harmonics and high power factor. To overcome this, all three phases must provide power simultaneously and the load must appear resistive. Figure 1 demonstrates the problem, showing essentially perfect voltage sinewaves, but highly distorted triangular current waveforms, with significant lag between current and voltage. Excessive current distortion and lag disrupts the power generation system since it must supply greater amounts of current where there is insufficient voltage. Designers must guard against power conversion designs that draw power this way. To ensure system reliability and optimize overall performance, the current waveform must be directly coincident, or in phase, with the voltage waveform. Marotta s 1-STEP converter draws power continuously from all phases, resulting in sinusoidal input current in phase with input voltage. In contrast to Figure 1, Figure 2 illustrates that when the load is purely resistive, current follows voltage and power factor is unity. Figure 1: Without power factor correction, low power factor and high input current harmonic distortion occur. Figure 2: 1-STEP appears resistive to the AC power, resulting in unity power factor and low input current harmonic distortion. 4

7 1-STEP Outperforms Existing Power Electronics Options Marotta streamlined circuit design, improved performance and reduced weight 1-STEP technology provides a significant advantage with its use of a single controller. With 1-STEP, load sharing is inherent, as its single DC output is controlled without the need for load sharing controls or individual current output measurements. Costs and complexity are reduced dramatically as a result. This is in contrast to designs without inherent load sharing, which need multiple feedback controls. 1-STEP handles this process by generating a single pulse width modulation (PWM) that balances the currents among the three DC outputs which are tied together. The 1-STEP circuit can easily link multiple modules to achieve output power capabilities as needed by the application. Solution Comparison Chart Three-Phase AC to Regulated, Isolated DC PPFC ATRU VIENNA 3 PFCs + 3 DC-DCs PFC Entire Load Range NO YES YES YES Requires Post DC-DC Conversion YES YES YES YES Regulation NO NO YES YES Output Voltage Level Follows the Input Follows the Input Boosted Voltage Isolation NO NO NO Stepped Up or Down Requires 2 Conversions Only with 2nd Conversion Wild Frequency NO NO YES YES Total Efficiency 90% (1) 89% (1) 89% (1) 91% Reliability 91, ,000 74,000 38,000 Weight Density, (W/lb.) Volume Density, (W/cu. in.) Technical Risk Low Low High Medium Cost Medium High High High YES NO YES Stepped Up or Stepped Down YES YES 93% 394, Low Low Passive Power Factor Correction: Passive power factor correction (PPFC) is more cost effective and less complex with the absence of active components, but requires increased inductance and capacitance. Solutions are heavy and limited to low power applications ranging from a kilowatt to ~1500W. Only effective at full load. ATRUs: ATRUs, like PPFCs, offer no regulation or isolation, requiring a secondary DC-DC conversion. Solutions are costly and heavy for SWaP-conscious, high performance applications. ATRU power density is just 300 watts per pound, while 1-STEP s is as high as 790 watts per pound. (1) Assumes post DC-DC conversion efficiency of 95% Vienna Rectifiers: Vienna rectifiers are complicated, with three switch-controlled rectifier circuits. The control scheme uses complex calculations to determine a separate control instruction set for each rectifier. Vienna offers no isolation and can only regulate to a boosted voltage without a second DC- DC conversion. 3 PFCs + DC-DC: Three-phase power processed as three lines of single phase power can be used; however this results in not one but two stages of power conversion to yield lowervoltage converted power. The solution is complex, requiring nine independent control circuits three single phase PFC, three DC converters and three load share circuits. 5

8 Test Results for 1-STEP AC-DC Conversion Technology All tests were performed with the 3kW version of 1-STEP Power Factor Correction Harmonics Test Testing was conducted using a calibrated power analyzer Yokogowa WT1800. As shown above, power factor is at at 60% of the load. Testing was conducted using a calibrated power analyzer Yokogowa WT1800. As shown above, Total Harmonics Distortion (THD) is 2.1%. The fifth harmonics is 1.448%. All single harmonics are shown. Power Factor & Efficiency vs Load Output Regulation vs Load High efficiency and unity power factor are achieved from 30% to 100% load. Over the entire load range, the output regulation remains constant, fluctuating within one-half of one percent. 6

9 Test Results for 1-STEP AC-DC Conversion Technology All tests were performed with the 3kW version of 1-STEP Input Current in Phase with Input Voltage 3 Phase Input Current 7

10 1-STEP is Validated for High-Performance Power Applications Learn How You can Gain Competitive Advantage and Better Performance with 1-STEP As modern aircraft and marine vessels migrate from mechanical, pneumatic or hydraulic systems to electrical equivalents, improvement in power conversion performance is essential. Marotta s 1-STEP technology outperforms existing power conversion options with streamlined design, improved performance, and reduced weight. 1-STEP has been designed and validated to key military and commercial avionics standards for electromagnetic interference and compatibility (EMI/EMC) as well as input power quality. In addition, 1-STEP offers compact size and high density performance advantages for shipboard 60Hz power applications. MIL-STD-461F: EMI/EMC requirements, validated for Navy MIL-STD-704A-F: Aircraft power quality for 115 VAC, 3-phase, 400 Hz power MIL-STD B for Type I Shipboard Power, 115 VAC 3-phase, 60 Hz: The design is also adaptable for 440 VAC input voltage Unlike any existing solution, 1-STEP provides input harmonic control, near unity power factor correction at full and partial loads, rectification of three-phase AC input, regulation of DC output, and isolation of the DC output from the AC input all in one control step. Circuitry is simplified, size and weight are minimized, and costs are reduced for both development and long-term performance. Because 1-STEP provides power factor correction inherent in its single conversion stage, the device achieves an overall high power conversion efficiency of up to 93%, with current harmonic distortion at 3% or less, automatic load sharing and modular scalability. Technical risk is low, as the device is validated for performance in compliance with a range of rigorous military and industrial electronics standards. By realizing 1-STEP s comprehensive improvements in size, weight, reliability, and cost, OEMs can distinguish their own systems and equipment capitalizing on high power conversion efficiency as a new opportunity for competitive edge and design innovation. DO-160G Sections 16: Power Input DO-160G Sections 18 through 22: EMI/EMC 1-STEP from Marotta Controls is designed to be tailored for specific applications with respect to shock, vibration, temperature and other environmental factors. Marotta s 1-STEP technology is a groundbreaking solution, addressing the evolving real-world needs of power electronics for military and industrial applications. # # # 1-STEP AC-DC Conversion Technology was invented by: Joseph F. Youssef Senior Electrical Engineer, CONTACT US TO LEARN MORE Steve Fox, Vice President of Engineering & Chief Technology Officer Media@Marotta.com 8

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12 78 Boonton Avenue P.O. Box 427 Montville, New Jersey USA All rights reserved. 1-STEP and the 1-STEP Logo are Patent-Pending as of May,

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