HelP - Hocheffiziente leistungsstarke Plasmastromquelle

Abstract

As part of the "HelP - Highly Efficient, High-Performance Plasma Power Source" project, an innovative power source for plasma cutting was developed that impresses with its increased efficiency and grid compatibility. The goal was to increase the efficiency of the power source through soft-switching converter topologies and reduce electrical energy consumption. The use of novel wide-bandgap semiconductors (silicon carbide SiC) enabled a significant reduction in switching losses. The project encompassed the conception, design, and control development, as well as the construction of functional prototypes and demonstrators. The results show a reduction in losses by almost tow thirds, with an efficiency of 95.8% at 8 kW. This resulted in a grid-friendly PFC rectifier circuit and a soft-switching current-controlled interleaved switching LLC resonant converter circuit. The partially successful implementation of the technical objectives and the preparation of a demonstrator for use in a plasma cutting system underscore the relevance of the project for energy efficiency in industry.