Medium Voltage Power Converter
Design and development of a 10kV SiC-based modular multilevel converter for industrial applications with 98.5% efficiency.
Role
Lead Power Electronics Engineer
Client
Industrial Research Project
Duration
12 months
Year
2024
Technologies
- ✓98.5% peak efficiency achieved
- ✓50% volume reduction compared to Si-based alternatives
- ✓THD < 3% at full load
- ✓Modular design for easy maintenance and scalability
This project involved the complete design, simulation, and prototyping of a medium voltage power converter utilizing Silicon Carbide (SiC) MOSFETs in a modular multilevel configuration. The converter achieves industry-leading efficiency of 98.5% while maintaining compact form factor through advanced thermal management.
Key Features
- 10kV input/output voltage rating
- 1MW power handling capability
- SiC MOSFET-based switching cells
- Advanced gate driver design with galvanic isolation
- Real-time FPGA-based control system
- Comprehensive protection schemes
Technical Approach
The modular multilevel converter (MMC) topology was selected for its scalability and inherent redundancy. Each submodule contains a half-bridge configuration with SiC MOSFETs, enabling high switching frequencies while minimizing losses.
The control system implements model predictive control (MPC) for optimal switching decisions, resulting in reduced harmonic distortion and improved dynamic response.