Study On High Power Switching Electroplate Power Supply Based On Modular And Soft-Switching

There are two forms of tinplate: hot-dip and plating. Hot dip which is inefficient andwastes resource has been gradually phased out. However, the way of plating has advantagesof low cost, high efficiency, stable quality and also can achieve different processes such as:single, double, etc. Nowadays, industrial production raised higher requirements ofelectroplating power in terms of quality, efficiency, stability and digitization with theimprovement in tinplate production technology. The traditional thyristor rectifier can not meetthe needs of the entire production line. On the other hand, a single high-power switchingelectroplating power supply has the disadvantages of stability and reliability. The productionline will be forced to close because of a electroplate power glitch.This research designed a high-power switching supply for electroplating is144kWoutput power based on building block design; its output is24V/6000A. The modular designimproves the stability of the plating power supply and can achieve redundancy control.System composed of four unit modules and each unit has its own controller module. Theentire system using a master-slave control mode, And the controllers uses DSP28335. Thedigital control system of DSP is designed. Finally, by using the improved digital averagecurrent control method to achieve the automatic current sharing between modules.The module selected the phase-shifted full-bridge zero voltage converter as main circuitand used soft-switching to improve power efficiency. A method design of the parameters andstructure of the main circuit is introduced and the components are selected. After, the designof hardware, especially the methods of IGBT’s drive, protection and testing is introduced.Also, the software’s flowchart based on DSP is given.On the basis of theoretical research, simulative results confirm the feasibility of thecontrol system. Finally, a24V/6000A power supply prototype is designed, including the maincircuit and the control principle diagram, PCB control board, and practical experimentalwaveforms are given.