Overview

The project Precision High Voltage Power Supply for Traveling Wave Tubes deals with design

and simulation of high voltage power supply to optimize the operating point to obtain desired output. The TWT requires an input voltage of 7KV. The aim was to design the supply using the series resonant converter topology with soft switching technique where the MOSFETs have to be operated at 200KHz frequency. MOSFET was chosen as the operating frequency is very high. A high frequency, high voltage transformer was designed to meet the space constraints. Initially a circuit with series resonant converter, transformer and a resistive load of 110K has been designed. Since, TWT is a tube which cannot be operated while doing the tests, an equivalent value of resistance of 110K has been used as a load. In this the MOSFETs has been operated using a planar transformer which will be operated as a driver circuit of MOSFETs. An output voltage of 7KV has been successfully achieved with this circuit. But when the load is less or in no load condition, the output obtained will be more than the desired value. So, with the help of S break switches an arrangement has been made to block the input to the MOSFETs for some time duration i.e when the output capacitor is discharging. Using this arrangement we are able to obtain the nearby value of the desired voltage. It has been decided to tap the output of the step up transformer to obtain 3 different voltages. When the circuit with above said components at primary side with tapings at the secondary side of the transformer was simulated, hardly an output of 5KV was obtained. 100s of simulations has been done by varying different parameters but the result was same. Thus it has been decided to go for the design which uses phase shifting technique for controlling the variations of the circuit and helps to attain the required output voltage. Thus an IC UCC 3895,a phase shift pwm controller ,has been utilized for the same. Alongside a MOSFET driver IC of HIP 4081 has been used. The phase controller IC is provided with proper values to the respective pins. The error amplifier of the UCC 3875 requires a sampling voltage less than 5V. So, the output voltage is stepped down in the ratio of 1000:1 to obtain the sampling voltage. The operating frequency has been adjusted by putting proper combination of timing resistor and capacitor with the help of appropriate formulae. Delay time between the switches are also calculated using the formulae. Calculation for the values of the rest of the devices are carried out in similar manner. On designing and simulating the circuit with HIP 4081, high voltage high frequency transformer, UCC 3895 and resistive load, still a precise value of voltage of 7KV was not achieved. To attain the same, a PI controller has been designed. While designing the PI controller, it was difficult to obtain the no load as well as full responses of the supply circuit since we are unable to give the step size more than 4 ns. This restriction was faced with the UCC 3895 IC which was downloaded. After many days of repetition we obtained the responses and PI controller has been designed. The same was implemented in hardware too. Due to the losses in the transformer some variations has been done in the values of the PI controller in practical implantation to attain the precise output of 7KV required by the TWT. Due to the time constraint the tapping of the transformer at the secondary side has not done with the circuit which uses ICs.