Design Concepts of Power Electronic Converters for Industries

A 3 month course which covers the design concepts of power electronic converters. The course is designed form an industry perspective with 2 projects

  • Pre-requisites : Understanding of circuit theory, power electronics basics, understanding of MATLAB & Simulink, and controls theory
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A Quick Overview

Power electronics is now one of the most popular area in industry to work on, apart from artificial intelligence, software development and data science. With evolution of electric vehicles, renewable energy and microgrids, power electronics is now one of demanding and specialized sector with plenty of opportunities.

This course on “Design of Power Converters for Industrial Applications” is helpful for Anyone who’s looking for career in electric vehicles, renewable energy, micro-grids, energy storage, power supply design can take the course. This could be a fresher undergraduate/graduate student, or a professional working in the industry with relatively few years of experience, or a professional looking to switch careers into electric vehicles and renewable energy application.

As part of this course, we will go through the basics of power electronics, switching methods, power converters and then dive into modelling those power converters and understanding how to design an actual converter that’s typical to industry. Some of the key topics will be Magnetics Design, Cooling System Design, Boost converter modelling & design and Inverter modelling & design. We will also model different power converters and review their performance, controls using MATLAB and PSIM.

The real-world applications include, being able to model & design inverter, dc/dc converters with strategies, calculations and understanding the critical parameters and design aspects which are not usually gained without experience in Industry. Power electronics is widely used across thousands of companies, but let’s pick the major ones –

EV sector – Tesla, Tata, Mahindra, Rivian, Ather Energy, Apple, Nio, Lucid Motors, Nikola, Sonalika Tractors, Volkswagen, BMW, Audi, GM etc
Power companies – ABB, Schneider Electric, GE, NTPC, ISRO etc
Power Supplies & Semiconductors – Murata, Chroma, Brusa, Infineon, Texas Instruments, Fuji, etc

For students taking this course, pre-requisite is that you understand circuit theory, power electronics basic, understanding of MATLAB & Simulink, and controls theory.


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COURSE SYLLABUS

1What is Power Electronics & It’s Industrial Applications

In this module, we will go through basics of power electronics, different types of power converters that’s used in industry and their application

  • Basics of power electronics
  • Type of Power Converters & it’s applications – DC/DC, AC/DC, DC/AC, AC/AC converters

2Power Converter Components and Design Standards

Successful design of Power converters requires efficient component selection. In this module, we will go through different power electronic components. 

Another major part of design is meeting different Industry standards, which we will overview as well

  • Introduction to Power components
  • Industry standards

3Power Switching Devices

Heart of every power converter is a switching device, and in this module we will learn which devices are used in different topologies, and why?

  • Types of power switching devices – MOSFETs, IGBT, SCR, Thyristor
  • Selection of switching device based on application
  • IGBT and MOSFET datasheet overview & analysis

4Power Switching Devices

We looked at classical power switching devices which have existed for more than 20 years. With evolution of semiconductor technology wide band gap devices are now popular with benefits of higher switching frequency, reducing the overall size of power converter. In this module, we will discuss:

  • Introduction to Wide band gap devices
  • SiC and GAN MOSFETs overview
  • Design and Processing of WBG power devices
  • Selection of WBG devices

5Switching Methods for Power Electronics Devices

This is one of the critical section, where we will learn how to operate a DC/DC converter or DC/AC converter by switching them with different methods, and understand their pros & cons

  • Different Switching Methods and Theory
  • Deep dive into Sinusoid PWM and Space Vector PWM strategy

6Controls Theory and Modeling of Closed Loop Buck Converter

Modeling of a power electronics converter in real-world application requires regulation of output voltage/current. In this chapter we will go though basics of control systems and transfer function derivation. We will also take the Boost Converter Design and analyze the transfer function

  • Basics of Control Systems
  • Laplace Transforms
  • Derivation of Transfer function
  • Analysis of transfer function of buck converter

7Introduction to Magnetics

Magnetic design is crucial in any power supply, DC-DC converter applications, gate driver design. In this module we will investigate different concepts of magnetic design and design a push pull transformer

  • Basics of magnetic design
  • Inductor Design
  • Design of gate driver transformer

8Power Electronic Topologies

First step of implementing the power converter is to determine which topology suits the desired application. In this module, we will go through different inverter topologies that’s used in industry.

  • Single Level Inverters
  • Multi-Level Inverters
  • Neutral Point Clamped Inverter
  • Matrix Converter
  • Cyclo Converter

9Single Phase Inverters

Inverters are one of the most essential power conversion devices, which can be found on UPS, TV, Electric Vehicles, Substations, almost every heavy machinery industries. In this module, we will understand the basics of inverter and single phase inverter design

  • Basics of Inverters
  • Single phase, three phase inverters
  • Modeling of 3 phase inverter

10Introduction to Electric Drives

Electric vehicle applications and other industrial applications rely upon rotating machines, and both DC & AC machines are widely used. In this module, we will learn about basics of electromagnetics and necessary background needed to understand AC machines

  • Fundamentals of electromagnetics
  • Types of Machines
  • Losses in Electric Machines
  • Intro to PMSM and IM

11Cooling System Design

This is where both electrical and mechanical design engineers should be very attentive, cooling system design is crucial for working of any high power converter design. In this module, we will look into types of heat losses in power electronics devices, and how to model them and design an efficient cooling system

  • Switching & Conduction Losses
  • Understanding the power losses from IGBT datasheet
  • Calculation of power loss for 3 phase inverter
  • Deriving efficiency of a 3 phase inverter
  • Design and selection of cooling system

12Snubbers & DC link Capacitor

While designing any high frequency power converter, the major challenges that a designer faces is on suppressing the switching transients on switching device. Since most of the failures on switching device are because of high voltage transients. In this last module, we will learn about Snubbers, their applications and design

  • Theory of Snubbers
  • Types of Snubber Topologies
  • Calculation of Snubber Parameters
  • DC link capacitors


Projects Overview

Project 1

Highlights

  • Extending the learned lessons in previous module, you will be diving into another power electronics concept on your own.
  • Design of boost converter, and calculating the loss of different components including power switching device and deriving efficiency of boost converter. This is applicable in power supply industry, electric vehicles etc where DC-DC converter is required to boost the voltage from DC source. All the aspects of this project with loss calculation, device selection, simulation etc are industry relevant.

Project 2

Highlights

This project is focused towards electric vehicle application using an Induction Motor. Student will have to take following steps for a successful model:

  1. Model 3 Phase Inverter using Simulink (model the parasitic as well) with a switching frequency of 10Khz using 3 phase Squirrel Cage Induction motor, using V/F method, open loop
    1. For Induction Motor model – use Asynchronous Machine from Simulink with Squirrel Cage Preset Model – 05 , for 100HP Motor
    2. For back emf to speed relation, assume a linear rate from 0.25 to 1, with speed changing from 500 RPM to 2000 RPM
    3. Plot speed, stator voltage (line to line) and frequency.
    4. Plot stator line voltage, phase current

    2. Use the 3 phase inductor motor theory to derive the transfer function of 3 phase Induction Motor

    3. Model 3 phase induction motor with a 3 phase inverter using Direct Torque control using an Average Model, Implement both torque and flux control to achieve desired power.


WHO IS THIS COURSE FOR ?


  • Anyone who’s looking for career in electric vehicles, renewable energy, micro-grids, energy storage, power supply design can take the course.
  • This could be a fresher undergraduate/graduate student, or a professional working in the industry with relatively few years of experience, or a professional looking to switch careers into electric vehicles and renewable energy applications.

SOFTWARE COVERED

MATLAB & Simulink

Matlab is one of the widely used simulation, software development, real-time simulation, Hardware in loop simulation tool for applications such as signal processing, circuit simulations, controls simulation, power electronics, aerodynamics, thermal design etc. In this course our focus will be on “Simscape” library within Simulink for circuit simulations and controls theory demonstration, and modeling of different converters.

We will also use matlab scripting, workspace etc for data processing and initialization scripts.

PSIM

PowerSim is another advanced tool for circuit simulation and controls, which is preferred more than MATLAB in Industry for power electronics. PSIM has advanced circuit blocks, non-linear models, capability to include SPICE blocks for semiconductors, non-linear models for electric machines, power electronics switch and mechanical loads. In this course, we will go through PSIM demo and several simulations using PSIM library blocks for power electronics circuit demonstration.

Mag-Inc Inductor Design Tool

Inductor design is another crucial part of good power electronics design, whether we need a low power or high- power inductor for filters. Mag Inc has different tools for magnetics, and Inductor design tool is pretty good to cover different design details which are difficult to cover through manual calculations.

In this course, we will go through Mag Inc inductor design tool, and Inductor simulation.


Frequently Asked Questions

1Who can take your course?

Anyone who’s looking for a career in electric vehicles, renewable energy, micro-grids, energy storage, power supply design can take the course. This could be a fresher undergraduate/graduate student, or a professional working in the industry with relatively few years of experience, or a professional looking to switch careers into electric vehicles and renewable energy applications.

2What is included in your course?

We will go through the basics of power electronics, switching methods, power converters and then dive into modelling those power converters and understanding how to design an actual converter that’s typical to industry. Some of key topics will be Magnetics Design, Cooling System Design, Boost converter modelling & design and Inverter modelling & design.

3What will the student gain from your course?

Student will understand the basics of power electronics (semiconductor physics, electrical, magnetics and mechanical concepts) and learn to create simulations and actual applications which are applicable to Industry.

4What software skills are you teaching and how well are these tools used in the industry?

We will go through the design & modelling of power electronics converters in Matlab, it’s extensively used in the Industry. We can also use PSIM, form some circuit simulations which is also used frequently in industry.

5What is the real world application for the tools and techniques will you teach in this course?

The real world applications include, being able to model & design inverter, DC/DC converters with strategies, calculations and understanding the critical parameters and design aspects which are not usually gained without experience in Industry.

6Which companies use these techniques and for what?

Power electronics is widely used across thousands of companies, but let’s pick the major ones – 

  • EV sector – Tesla, Tata, Mahindra, Rivian, Ather Energy, Apple, Nio, Lucid Motors, Nikola, Sonalika Tractors, Volkswagen, BMW, Audi, GM etc
  • Power companies – ABB, Schneider Electric, GE, NTPC, ISRO etc
  • Power Supplies & Semiconductors – Murata, Chroma, Brusa, Infineon, Texas Instruments, Fuji, etc

 

7How is your course going to help me in my path to MS or PhD?

We will go through the course structure and dive deep into implementing the technology learned during BE or B.Tech, which will be similar to MS or PhD interms of complexity but also oriented towards Industry. Certain tips & expectations from Professors in US/Canada on this course and how to prepare for it will be covered 

8How is this course going to help me get a job?

At the end we are looking to gain the skills and be able to apply those in Industry. The tools and power electronics lessons will go into present a thorough understanding of the process that’s used in Industry by a typical power electronics engineer, power electronics mechanical engineer, systems engineer.

 


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  • Access Duration : 2 Months
  • Mode of Delivery : Online
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