[Req] 12kW, 5KV Capacitor Charging Power supply design Help

[itp]

Hi All,
I have to design and develop a 12kW, 5 KV Capacitor Charging Power supply for a client. A resonant converter topology is preferable. Experience persons Kindly suggest tutorials/links/simulation software etc.

Thanks and regards
Itp

[medik]

I have seen a boost dc dc converter of 12kW at 400V 30A Max. From your requirements less than 3A is needed.
 I advise that you build a scaled down version of say 500W before going to experiment with high 12kW.

You did not state the input voltage source and level. Is it going to run off batteries?

[itp]

Hi medik,

It will be operated from three-phase (420V) supply.

Regards
itp

[roscoe]

There are a few approaches that could work here -- you could use something like a SEPIC style boost w/ a transformer and then a ladder multiplier.  You probably don't care *too* much about ripple since you're just charging caps.  The downside is that it will take a while to charge them like this.

Alternatively, you could look for an IGBT and switch rectified voltage.

[Gallymimu]

I've built these before.  The best design is resonant as you suggest so you can take advantage of high queue to get the MANY X boost you need.  This is NOT a trivial design.

The last time I did it was 15KW from 208V 3  phase input for 800V output, open circuit however it was 5000V.

A trick you can use with LLC is that you can get both Ls in one leakly solenoid (leakage inductance makes one L and magetizing inductance makes the other)  full bridge IGBT resonant 100KHz to 500KHz worked out well for us.

It was a beast of a design and cost about $1m to develop.  Granted it had a graphical UI, industrial comm protocols, 1% measurement and accuracy, and could survive high frequency plasma arcs on the output (very low stored energy output).

I hope you are a VERY experienced power designer.  This is NOT an easy design.

Also be careful of corona, you will have a problem with it on the edges of traces of our PCB outer layers.

[itp]

Hi all,
Can you suggest any published journal papers on this topic. Searching on google will definitely fetch lot of results. But I would rather prefer Experts in this field suggest some relevant papers.

Thanks and regards
Itp

[Sat]

Hi Itp,

Use two stage power conversion for your application (AC to DC front end converter for 420Vac to 800 VDC conversion. A ZVS phase shifted interleaved fullbridge for 800VDC to 5KVDC)   

Try  VIENNA rectifier for front end converter purpose.

https://en.wikipedia.org/wiki/Vienna_rectifier

Use multiple outputs in fullbridge (8 outputs, each output voltage is 625V). After rectification add all these outputs in series connection to get 5KV.

i hope your are expert in power electronics design, because it is very tough requirement. I suggest to you initially make a scale down (1.2KW) prototype.

Thanks,
Sat

[2N5109]

Here is a useful link for you:
 https://files.acrobat.com/a/preview/d3aeb95b-8d7d-4f26-a078-6dbf721e8f1d

Good luck, 5kv is not so bad. I have built 10kv pulse power frozen wave generators with careful lab procedures.

--2N5109

[Diramo]

Hi. Ten years ago I built power pulse generator with hydrogen thyratron, the average output power was 10KW, pulse voltage 25KV.
I used resonant bridge converter for pulse forming network charging. My design was based on the publication, attached below.