Open Access
High frequency power transformers with foil windings: maximum interleaving and optimal design
(IEEE, 2015) Barrios Rípodas, Ernesto; Urtasun Erburu, Andoni; Ursúa Rubio, Alfredo; Marroyo Palomo, Luis; Sanchis Gúrpide, Pablo; Ingeniería Eléctrica y Electrónica; Ingeniaritza Elektrikoa eta Elektronikoa; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
Foil conductors and primary and secondary interleaving are normally used to minimize winding losses in high frequency transformers used for high-current power applications. However, winding interleaving complicates the transformer assembly, since taps are required to connect the winding sections, and also complicates the transformer design, since it introduces a new tradeoff between minimizing losses and reducing the construction difficulty. This paper presents a novel interleaving technique, named maximum interleaving, that makes it possible to minimize the winding losses as well as the construction difficulty. An analytical design methodology is also proposed in order to obtain free cooled transformers with a high efficiency, low volume and, therefore, a high power density. For the purpose of evaluating the advantages of the proposed maximum interleaving technique, the methodology is applied to design a transformer positioned in the 5 kW 50 kHz intermediate high frequency resonant stage of a commercial PV inverter. The proposed design achieves a transformer power density of 28 W/cm3 with an efficiency of 99.8%. Finally, a prototype of the maximum-interleaved transformer is assembled and validated satisfactorily through experimental tests.
Open Access
Toroidal inductor design in multilevel DC-DC electric vehicle battery charger including high-frequency effects
(IEEE, 2022) Elizondo Martínez, David; Barrios Rípodas, Ernesto; Sanchis Gúrpide, Pablo; Ingeniería Eléctrica, Electrónica y de Comunicación; Institute of Smart Cities - ISC; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
Inductor filters, such as the ones implemented in DC-DC buck-boost converters for electric vehicle chargers, have a major impact on the converter weight, volume and cost. Thus, their design is key in order to obtain an optimal design of the whole converter. This paper proposes a design methodology for powder core toroidal inductors, which is based on a holistic approach of the design of the inductor, where losses due to highfrequency effects are computed by means of specific loss model for toroidal windings, and saturation, geometrical and thermal constraints are considered. The convenience of the design tool is shown through an analysis over a wide variation of parameters, including converter topology, parallelization, switching frequency and inductance. The analysis demonstrates the relevance of high-frequency effects on the inductor design, so certain misconceptions can be avoided, such as that the inductor volume monotonically decreases when the inductance value is decreased or that paralleling inductors always results in more compact designs. A design example is presented for a 15-kW, three-level electric vehicle battery charger. The algorithm is used to obtain an optimal design of the converter, including the inductors and SiC MOSFET devices. Finally, an easy method to obtain a commercial inductor design from the theoretical one provided by the algorithm is presented.
Open Access
The generalized bode criterion: application to the dc voltage control of a three-phase photovoltaic grid-tied inverter
(IEEE, 2019) Lumbreras Magallón, David; Barrios Rípodas, Ernesto; Urtasun Erburu, Andoni; Sanchis Gúrpide, Pablo; Institute of Smart Cities - ISC; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
As renewable energies are becoming more important in the electrical generation system, power electronic converters are facing new design issues related not only to their components but also to their control loops. In this context, the Generalized Bode Criterion (GBC) appears as a good tool to correctly determine stability and to help the controller design. In order to show the potential of the GBC and how it can be applied, this paper studies a dc voltage regulation with compensation of the photovoltaic power in a three-phase photovoltaic grid-tied inverter.
Open Access
On the impact of high-power grid-connected thyristor rectifiers on the efficiency of hydrogen electrolyzers
(IEEE, 2024-08-30) Iribarren Zabalegui, Álvaro; Barrios Rípodas, Ernesto; Rivera, Marco; Wheeler, Patrick; Sanchis Gúrpide, Pablo; Ursúa Rubio, Alfredo; Ingeniería Eléctrica, Electrónica y de Comunicación; Ingeniaritza Elektrikoa, Elektronikoa eta Telekomunikazio Ingeniaritza; Institute of Smart Cities - ISC; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
This paper investigates the impact of power supply and dc current ripple on the efficiency of water electrolyzers and demonstrates that optimally sized thyristor rectifiers meeting grid power quality regulations can effectively supply high-power electrolyzers with minimal impact on electrolyzer efficiency. Firstly, an equivalent electrical model for the electrolyzer is developed, and the efficiency reduction caused by dc current ripple is analyzed. This is validated by means of experimental data from a 5-kW alkaline electrolyzer operated with both thyristor- and IGBT-based rectifiers. Next, the paper explores the operation of high-power electrolyzers supplied by 6- and 12-pulse thyristor rectifiers complying with grid power quality standards. Results show that with optimal sizing of ac-side source voltage and filtering inductances, these solutions exhibit negligible dc current ripple impact on electrolyzer efficiency. These findings, validated through simulation of a 5.5 MW electrolyzer, highlight the viability of thyristor rectifiers in high-power electrolysis applications, and emphasize the importance of an optimal power supply design and sizing for enhancing water electrolyzers' performance.
Open Access
Analytical modeling of high-frequency winding loss in round-wire toroidal inductors
(IEEE, 2020) Elizondo Martínez, David; Barrios Rípodas, Ernesto; Sanchis Gúrpide, Pablo; Ursúa Rubio, Alfredo; Ingeniería Eléctrica, Electrónica y de Comunicación; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
Toroidal inductors are present in many different industrial applications, thus, still receive researchers' attention. AC winding loss in these inductors have become a major issue in the design process, since switching frequency is being continuously increased in power electronic converters. Finite element analysis software or analytical models such as Dowell's are the main existing alternatives for their calculation. However, the first one employs too much time if different designs are to be evaluated and the second one lacks accuracy when applied to toroidal inductor windings. Looking for an alternative that overcomes these drawbacks, this paper proposes an accurate, easy-to-use analytical model, specifically formulated for calculating high-frequency winding loss in round-wire toroidal inductors.
Open Access
Asymmetrical firing angle modulation for 12-pulse thyristor rectifiers supplying high-power electrolyzers
(IEEE, 2023) Iribarren Zabalegui, Álvaro; Barrios Rípodas, Ernesto; Elizondo Martínez, David; Sanchis Gúrpide, Pablo; Ursúa Rubio, Alfredo; Ingeniería Eléctrica, Electrónica y de Comunicación; Institute of Smart Cities - ISC; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
This paper presents an asymmetrical firing angle modulation strategy for 12-pulse thyristor rectifiers aimed at supplying high-power electrolyzers, which allows to reduce the size of the passive filter and the static compensator (STATCOM) required to comply with grid harmonic regulations and achieve unity power factor. Usually, 12-pulse thyristor rectifiers follow a symmetric modulation strategy in which the same firing angle is applied to both 6-pulse bridges. In this case, large passive ac-side inductances are required to reduce grid current harmonics, which increase the reactive power consumption and thus the required STATCOM size. However, this paper demonstrates that by applying different firing angles to the two 6-pulse bridges it is possible to comply with the harmonic regulation limits using smaller filtering inductances and therefore reducing the STATCOM size. The methodology to find the optimal firing angle values that should be applied in order to minimize the filtering inductance and the STATCOM size for a given electrolyzer is explained. This strategy is validated by simulation, and results show that the required filtering inductance and the apparent power of the STATCOM can be effectively reduced by 62% and 31%, respectively, using this asymmetrical firing angle modulation.
Open Access
Dynamic modeling of a pressurized alkaline water electrolyzer: a multiphysics approach
(IEEE, 2023) Iribarren Zabalegui, Álvaro; Elizondo Martínez, David; Barrios Rípodas, Ernesto; Ibaiondo, Harkaitz; Sánchez Ruiz, Alain; Arza, Joseba; Sanchis Gúrpide, Pablo; Ursúa Rubio, Alfredo; Ingeniería Eléctrica, Electrónica y de Comunicación; Institute of Smart Cities - ISC; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
In this paper a dynamic model for the simulation of pressurized alkaline water electrolyzers is presented. The model has been developed following a multiphysics approach, integrating electrochemical, thermodynamic, heat transfer and gas evolution processes in order to faithfully reproduce the complete dynamical behavior of these systems. The model has been implemented on MATLAB/Simulink and validated through experimental data from a 1 Nm3/h commercial alkaline water electrolyzer. Validations have been performed under real scenarios where the electrolyzer is working with power profiles characteristic from renewable sources, wind and photovoltaic. The simulated results have been found to be consistent with the real measured values. This model has a great potential to predict the behavior of alkaline water electrolyzers coupled with renewable energy sources, making it a very useful tool for designing efficient green hydrogen production systems.
Open Access
Control design and stability analysis of power converters: the discrete generalized Bode criterion
(IEEE, 2021) Urtasun Erburu, Andoni; Samanes Pascual, Javier; Barrios Rípodas, Ernesto; Sanchis Gúrpide, Pablo; Ingeniería Eléctrica, Electrónica y de Comunicación; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren
For the controller design and stability analysis of power electronic converters, the Bode stability criterion and its subsequent revisions are the most practical tools. However, even though the control of the power converter is usually implemented in a microprocessor, none of these methods is infallible when applied to a discrete system. This article therefore proposes a new stability criterion, named the Discrete Generalized Bode Criterion (DGBC). This method is based on the Nyquist criterion but developed from the open-loop Bode diagram, evaluated also at 0 Hz and at the Nyquist frequency. The proposed criterion combines the advantages of the Nyquist and Bode criteria, since it is always applicable and provides an interesting and useful tool for the controller design process. The method is applied to design an active damping control of an inverter with LCL filter, showing how the proposed criterion accurately predicts stability, in contrast to the existing Bode criteria. The theoretical analysis is validated through experimental results performed with a three-phase inverter and an LCL filter.
Open Access
Modeling and optimal sizing of thyristor rectifiers for high-power hydrogen electrolyzers
(IEEE, 2025-05-01) Iribarren Zabalegui, Álvaro; Barrios Rípodas, Ernesto; Sanchis Gúrpide, Pablo; Ursúa Rubio, Alfredo; Ingeniería Eléctrica, Electrónica y de Comunicación; Ingeniaritza Elektrikoa, Elektronikoa eta Telekomunikazio Ingeniaritza; Institute of Smart Cities - ISC; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
Thyristor rectifiers are currently the most common solution for supplying high-power electrolyzers. These rectifiers typically include a dc inductance, which significantly increases system costs. However, this inductance can be avoided by relying solely on ac-side inductances, required for grid current harmonic filtering, although this approach introduces specific challenges. Traditional analytical models of thyristor rectifiers are unable to determine the electrolyzer operating point for a given firing angle and may lead to incorrect system sizing, ultimately preventing the converter from delivering nominal power. This limitation arises from the fact that existing models are formulated for inductive or constant-current loads, whereas electrolyzers exhibit electrical behavior closer to constant-voltage loads. In this paper, a novel analytical model of 6- and 12-pulse thyristor rectifiers with constant-voltage load is developed. The model enables the analysis and optimal sizing of thyristor rectifiers directly connected to electrolyzers without a dc-side inductance. Its accuracy has been validated through both simulations and experimentally using a laboratory-scale prototype. Furthermore, the model has been applied to optimally size a 12-pulse rectifier supplying a 5.5 MW electrolyzer, demonstrating its suitability for the design of thyristor rectifier systems in industrial-scale electrolysis applications and highlighting its advantages over traditional approaches.
Open Access
Control design and stability analysis of power converters: the MIMO generalized bode criterion
(IEEE, 2020) Samanes Pascual, Javier; Urtasun Erburu, Andoni; Barrios Rípodas, Ernesto; Lumbreras Magallón, David; López Taberna, Jesús; Gubía Villabona, Eugenio; Sanchis Gúrpide, Pablo; Ingeniaritza Elektrikoa, Elektronikoaren eta Telekomunikazio Ingeniaritzaren; Institute of Smart Cities - ISC; Ingeniería Eléctrica, Electrónica y de Comunicación
Three-phase dynamic systems and multiphase generators are frequently modeled and controlled in the synchronous reference frame. To properly model the cross-coupling terms in this reference frame, complex vector theory and transfer function matrices are commonly applied, obtaining multiple-input multiple-output (MIMO) dynamic models. The stability of MIMO systems can be assessed through the Nyquist generalized stability criterion. However, the use of the Nyquist diagram complicates the controller design. The Bode diagram is a more intuitive tool for the controller design; however, the Bode stability criterion is not applicable to MIMO systems. In this article, the MIMO generalized Bode criterion is proposed. Since this stability criterion is based on the Nyquist generalized stability criterion, it can be applied to any system. Furthermore, it is simple to use, as it only requires information contained in the open-loop transfer matrix and the Bode diagram. The proposed stability criterion thus offers an interesting tool for the controller design procedure in MIMO systems, as it is shown in this article for two common applications: the current control loop of a power converter, a 2 × 2 system, and the current control loop of two independent power converters in parallel, a 4 × 4 system.