Design and Implementation of Magnetron Power Supply and Emulator

Nourdeen A. Abodhir, Alan J. Watson, Chao Ji, Jon C. Clare

University of Nottingham, Nottingham, NG7 2RD, U.K.
Email: [email protected]

Key words:
Resonant converter control, variable load, magnetron

Abstract
The paper presents a novel resonant based high performance power converter solution for industrial
magnetron systems. Based the characteristics of the magnetron, an emulator prototype is also
proposed to represent the magnetron load behaviour in a laboratory environment. A detailed design
and implementation procedure is presented, including the design and control of the resonant power
converter, together with the magnetron emulator in practical aspects. Experimental results are
provided in order to demonstrate the feasibility of the proposed converter and emulator.

1-Introduction
Industrial magnetrons are becoming increasingly more common in a wide range of applications such
as the production of food-stuffs, chemicals, textiles, paper and wood materials [1]. Since a high DC
voltage is required in order to drive magnetrons, the heart of any microwave energy generator
contains a high voltage DC power supply [2]. Traditional drive systems for high power radio
frequency (RF) applications such as Magnetrons and Klystrons are based on 50/60 Hz line frequency
voltage scaling components, which implies a bulky system volume.
Resonant power converters have been considered for their high efficiency and high power density
features to replace the traditional approaches. The main advantage of using the resonant converters
with high-frequency operation is the smaller size and lighter weight of the passive components used
[3]. Also, as demonstrated in [4], it is possible to operate the semiconductors at these higher
switching frequencies without significantly compromising converter efficiency.
For various target applications, different load resonant converter topologies with associated
modulation and control techniques, such as combined frequency and phase shift modulation (CFPM)
and DQ modelling, have been proposed in previous work [5-8]. The CFPM modulation technique can
be applied directly to modulate high power resonant converters with fixed load conditions. However,
in some industrial microwave applications, it is required to operate with a wide operating range for
different output requirements. This essential feature results in a variable load resistance seen by the
power converter, which not only affects the converter control and modulation, but also compromises
the soft-switching scheme.
With the aim of overcoming the aforementioned limitations, a control method based on three
dimensional (3D) lookup tables approach has been developed in order to modulate the load resonant
converter whilst maintaining soft switching under variable load conditions. For this method the soft
switching points for a whole operating range are pre-calculated and represented in a 3D lookup table.
Hence, during the converter modulation, the soft switching point (Zero Current Switching ZCS or
Zero Voltage switching) can be tracked by obtaining the online value of the variable load resistance
(consequently the load Quality Factor can be calculated) and the control actuation signal.
In this paper a compact power converter is designed to supply a magnetron under variable load
conditions. Since the quality of the produced RF energy is a function of Magnetron’s Anode current, a
controllable current source is formed, using the load resonant converter in the form of a Series
Resonant Series Loaded (SRSL) converter topology. In order to examine the proposed converter
topology and associated control strategy, and to avoid unnecessary cost and the production of high
voltage; a reduced scale power electronics based magnetron emulator was also proposed and
developed.
2-Proposed converter
Figure 1 shows the topology of the proposed SRSL power converter for industrial magnetron drives
which comprises of a three phase rectifier, DC link capacitors, H-bridge inverter, resonant tank,
transformer, rectifier, filter, magnetron equivalent circuit, associated measurement and control system.

Figure 1 SRSL based power converter topology for industrial magnetron drives.

The single phase full bridge inverter excites the resonant tank with a high frequency quasi-square
wave voltage. The high frequency, high voltage transformer is utilised to step up the voltage to the
necessary level required by the magnetron load. The tank current is rectified and filtered by using a
diode bridge rectifier and a capacitance filter to produce a smooth DC output voltage. The input three-
phase rectifier can be excluded from the scope of operation analysis and the DC-link capacitor can be
treated as a constant DC voltage source.

For simplicity, in the following design and steady state analysis the load is modelled as resistive load,
(R). By assuming that the resonant tank is reasonably selective and the inverter is switched around the
resonant frequency, the fundamental mode approximation can be utilised to simplify the inverter
output analysis [3]. The equivalent circuit of the proposed converter is shown in figure 2, while the
specifications and design results are listed in table I.

Figure 2 the equivalent circuit of the proposed converter

Table I: power supply specifications and design results

Description Symbol Value Description Symbol Value
Load voltage Vf 180V-300V Tank inductor L 0.787mH
Load voltage
Vripple <3% Tank capacitor C 72 nF
ripple
Design
Power Load current Iout 6A-10A Resonant frequency fo 21.14kHz
Results
Supply Output power P 1.8kW-3kW Filter capacitor Cf 9.6μF
Specifications Quality factor Q 2.5 - 5 Emulator capacitor Cemulator 160 μF
Switching
Fsw 21.2-24.3kHz Emulator resistor Remulator 15ohm
frequency
DC-Link voltage VDC 400V Slope resistor Rslope 5ohm
3-Magnetron Emulator
For an industrial magnetron, the quality of the produced radio frequency RF energy is a function of
the anode current. The typical relationship between the magnetron anode voltage and current is shown
in figure 3. The increase in the anode voltage causes insignificant rise in the anode current until a knee
voltage Vknee, is reached. After this knee voltage point the current is raised dramatically giving a
dynamic slope resistance (Rslope). For the industrial magnetron to work, the applied anode voltage
must be greater than the knee voltage (Va >Vknee).

Figure 3 the typical relationship between the anode voltage and current

From figure 3 it can be seen that it is possible to adjust the knee voltage point by increasing the
magnetic field. In order to vary the output power, either the knee voltage can be changed by varying
the magnetic field applied to the tube as depicted in Figure 3 in green triangular points, or by varying
the current at particular knee voltage as shown in the blue rectangular points. A combination of the
two can also be applied as illustrated in red circular points. The latter combination could result in
supplying the magnetron with constant power and the possibility of higher RF efficiency illustrated by
the efficiency contours. In order to control the magnetron at these various operating points, a variable
output high voltage power supply is needed. It should be noted that the characteristics of this tube
have not been scaled for testing.

The magnetron model is very important for the circuit design and simulations. The anode voltage and
current characteristic can be modelled as a slope resistor and variable dc source corresponding to the
knee voltage Vknee [9]. Figure 4 shows the simple model of the electrical equivalent circuit of the
magnetron with these characteristics.

Figure 4 simple model of the electrical equivalent circuit of the magnetron

The variable DC supply is set to certain values to represent the required knee voltage and emulate the
magnetron characteristics. The challenge is how to implement this model practically without using a
magnetron. Due to the lack of wave guide and variable output RF energy, the magnetron cannot be
driven in a power electronic laboratory. Therefore the magnetron characteristics will be emulated by a
novel reduced scale power electronic prototype to validate the proposed control method for the SRSL
resonant power converter.
A reduced scale power electronic prototype was proposed and developed in order to emulate the
magnetron characteristics. Figure 5 shows the proposed magnetron emulator and its associated
hysteresis controller.

Figure 5 reduced scale prototype magnetron emulator

The emulator consists of a resistor (Remulator), capacitor (Cemulator) and IGBT switch. A hysteresis
control was used to control the IGBT in order to obtain the required knee voltage. However the anode
current was regulated by using the SRSL converter’s controller. The hysteresis control comprises two
comparators and SR Flip-Flop logic circuit as depicted in figure 5.

This magnetron emulator has two modes of operation. For example if the required knee voltage
(VKnee) is set in a certain value with a voltage ripple (∆V). In mode 1 when the IGBT is OFF, the main
resonant converter charges the capacitor, Cemulator, until it reaches the value of reference 1 where the
ΔV
value is set as ( Vknee + ). At this point the hysteresis control will turn ON the IGBT and mode 2
2
starts. In mode 2, the IGBT is ON and the capacitor Cemulator will be discharging until it reaches the
ΔV
value of reference 2 which is set as ( Vknee − ), at this point the hysteresis control will turn OFF the
2
IGBT and again back to mode 1.

4-Modelling and Control Strategy

The modelling of the load resonant converters is different from conventional power converters, due to
the nature of the state variables such as the resonant inductor current and resonant capacitor voltage.
Authors in [5, 6] have demonstrated that the DQ modelling technique can represent the load resonant
converter dynamics and steady state behaviour accurately. In this paper the DQ method is applied to
model the proposed single-phase SRSL converter.

Figure 6 shows the equivalent DQ circuit of the SRSL converter, where Vsd is the fundamental
component of the tank input voltage, K is a parameter used to refer the output capacitance and
resistance to the input, Iout is the output current associated with the DQ model . K and Iout are defined
as in (1) and (2) respectively.

8
k= (1)
π 2 *n2
2
2  Ed 2  Eq 
I out =
n*π
 + (2)


KR   KR 
 Figure 6 the equivalent DQ circuit of the SRSL converter

In order to validate the DQ modelling method, two PLECS models have been developed. These
models are: the resonant converter model as shown in figure 1 and the developed DQ model as shown
in figure 6. The simulation applies open loop control with step change in the input voltage (i.e. the DC
link voltage changes from 561V to 700V at 0.007s). This condition is chosen simply to validate the
model under the transient conditions. The transient in figure 7 clearly shows consistency in accuracy
of the modelling.

Figure 7 Output comparisons between converter model and DQ model

Based on the DQ model, the system transfer function can be obtained, which is utilised in closed loop
control design. The use of varying frequency modulation introduces a continuously changing dynamic
and transfer ratio. In order to avoid instability, a large damping ratio is recommended according to the
previous experience [3].

The SISO tool in MATLAB was used to design a PI controller according to the obtained system
transfer function. This PI controller was designed to ensure a smooth dynamic response and a wide
stability margin. Equation 3 expresses the designed controller at 20 kHz sampling frequency, which
brings a gain and phase margin to 6.2 dB and 83.4o respectively.

1.6 (z -0.072)
GPI ( z)= ---------------------- (3)
(z -1)
5-Modulation
The combined frequency and phase modulation (CFPM) method which described in [5, 10-13] is
employed to modulate the load resonant converters. This method can minimise the semiconductor
switching losses and thereby ensure high conversion efficiency. The implementation of the CFPM
modulation is shown in Figure 8. Moreover, the equations (4) and (5) provide the expression of the
converter modulation index, MI, and phase shift between the tank voltage and current, φ, where, F is
the frequency ratio between the switching frequency and tank resonant frequency and Q is the loaded
quality factor.

Figure 8 implementation of the CFPM modulation

F2
MI = (4)
( F 4Q 2 + F 2 +Q 2 −2 F 2Q 2 )
ϕ = arctan[Q.( F − F −1 )] (5)

The CFPM modulation is based on an assumption of constant load condition [5, 10]. This implies that,
it is difficult to ensure the soft-switching via the CFPM modulation when the load resistance varies.

A novel control method has been proposed and developed in order to control the load resonant
converter whilst maintaining soft switching under variable load conditions. This method utilises a 3D
lookup table which characterises the soft switching of the converter and via a Q estimation method.
The correct voltage and output frequency are selected to control the Magnetron operating point whilst
achieving ZCS on the lagging leg of the converter.

In the applications where the load resistance can be evaluated through the load voltage and current
such as cavity magnetrons, the load quality factor Q can be estimated accurately. The normalised F in
equation 4 can be derived by combining the Q with the modulation index produced by the feedback
current control loop and DC-link measurement. Moreover, the corresponding phase shift in equation 5
that retains soft-switching can be also obtained. As a result, the influence of the variable load on the
soft-switching scheme can be overcome.

To implement the 3D lookup table, the frequency ratio points need to be pre-calculated across the
entire converter operating range. A 3D surface of F is plotted as a function of MI and Q as shown in
figure 9. The MATLAB surface fitting toolbox is utilised to fit this surface with a 4x4 polynomial
equation, which guarantees a fast and accurate evaluation of the frequency ratio for practical digital
control implementation.
 Figure 9 the nominal frequency as a function of the MI and Q

The approximation fitting equation 6 was obtained and implemented in both a c-script in PLECS for
simulation and in the control platform for experimental work in order to derive the switching signals
patterns for the SRSL converter.

F = 2.195 − 0.9689Q + 1.754 MI + 0.2068Q 2 + 1.221Q × MI − 8.977 MI 2 − 0.02326Q 3 − 0.1345Q 2 × MI − 0.7746Q × MI 2 (6)
+ 0.48 M 3 + 0.0009199Q 4 + 0.009949Q 3 × MI − 0.0007299Q 2 × MI 2 + 0.3496Q × MI 3 − 4.28 MI 4

Figure 10 shows the block diagram of the novel 3D look up table based CFPM modulation approach.
During the converter modulation, the soft switching point (updated F and φ which ensure soft
switching commutation) can be tracked by obtaining the online value of the variable load
resistance (From Q estimator) and the control actuation signal (From the output current
control).

Figure 10 block diagram of the novel 3D look up table based CFPM modulation approach.

6-Simulation and Experimental Results

The reduced voltage prototype was set up according to figure 1, with a fixed DC source representing
the rectified supply from the mains. The transformer was omitted and the resonant tank was directly
connected to the rectifier bridge to minimise the cost. The proposed magnetron emulator was used as
a load to emulate the magnetron characteristics. The image of the 400V, 3kW experimental prototype
converter is shown in Figure 11.
 Figure 11 Overview of the experimental prototype converter

Figure 12 shows the knee voltage including the output ripple voltage ∆V, Figure 12a shows a PLECS
simulation for the knee voltage when the hysteresis control is set to give 214V average knee voltage
with 2V output voltage ripple. Figure 12b shows an experimental result for the same setting. It is clear
that the hysteresis controller could regulate the knee voltage accurately.
218 218
217 217
Knee Voltage (V)

Knee Voltage (V)

216 216
215 215
214 214
213 213
212 212
211 211
210 210
3.24 3.242 3.244 3.246 3.24 3.245 3.25 3.255 3.26
time(sec) time(sec)
(a) (b)
Figure 12 the knee voltage, (a) simulation results, (b) experimental results

Figure 13 shows a PLECS simulation and experimental result for the knee voltage when the hysteresis
control is set for step changing the voltage from 214V to 205V average knee voltage with 2V output
voltage ripple.
218 218
216 216
214 214
212 212
210 210
208 208
206 206
204 204
202 202
3.2 3.3 3.4 3.5 3.6 3.2 3.3 3.4 3.5 3.6
time(sec) time(sec)
(a) (b)
Figure 13 step change of the Knee voltage, (a) PLECS simulation, (b) experimental verification

The hysteresis controller is able to change the knee voltage from 214V to 205V. The change in the
knee voltage will emulate the change in the magnetic field applied to the tube in the real magnetron.
Figure 14 shows a step change of the output current reference from 7.3A-8.7A (consequently the Q is
step changed) in order to test the transient behaviour of the novel control method and also to prove
that the resonant converter control could drive variable load nature. The change in the reference
current will emulate the change in the anode current in the real magnetron. A combination of both the
knee voltage and the reference current can be applied in order to find the most efficient RF generation
point for a given load.

Output Current (A)

Output Current (A)

Quality Factor Q
Quality Factor Q

(a) (b)
Figure 14 step change of the output current and Q (a) simulation results (b) experimental verification

Figure 15 shows the simulation and experimental the current and the voltage waveforms of the
resonant tank. The IGBTs in the lagging leg are always switched at the zero crossing point of the tank
current, while the ones in leading leg have soft switching-on and hard switching-off.
400 40
300 30
200 20
Voltage (V)

Current (A)
Voltage (V)

Current (A)
100 10
0 0
-100 -10
-200 -20
-300 -30
-400 -40
400 450 500 550
time( sec)
(a) (b)
Figure 15 the resonant tank voltage and current, (a) simulation results, (b) experimental verification

A snubber capacitor was utilized to achieve zero-voltage switching off. Consequently, soft-switching
can be obtained at full power in all the IGBTs, which ensures high conversion efficiency. The
experimental results present a very close match with the simulation results.

7-Conclusions
The SRSL converter has been introduced as a compact and efficient power supply for variable load
conditions, such as those that may be present in industrial microwave processing systems. Moreover,
a magnetron emulator has been designed and implemented in order to practically emulate the
magnetron characteristics. Soft switching was achieved for all power devices ensuring a high
efficiency. Moreover, the stability of the proposed controls (CFPM integrated with Q estimator and
the hysteresis control for the magnetron emulator) was also successfully verified. PLECS simulation
and experimental verification demonstrate the proposed converter and the magnetron emulator. The
figures show good correlation between the simulation and experimental results. It can be concluded
that the proposed converter topology and the control approach are feasible in practice for a higher
power system.
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