The Development of High-Current Power Supply System for Electrolytic Copper Foil

摘要

A 6.5 V/50 kA high-frequency switching power supply (HSPS) system composed of 10 power modules is developed to meet the requirements of copper-foil electrolysis. The power module is composed of a two-leg pulse width modulation (PWM) rectifier and a DC/DC converter. The DC/DC converter adopts two full-wave rectifiers in parallel to enhance the output. For the two-leg PWM rectifier, the ripple of the DC-link voltage is derived. A composite control method with a ripple filter is then proposed to effectively improve the performance of the rectifier. To meet the process demand of copper-foil electrolysis, the virtual impedance-based current-sharing control method with load current full feedforward is proposed for n-parallel DC/DC converters. The roles of load current feedforward and virtual impedance are analyzed, and the current-sharing control model of the HSPS system is derived. Virtual impedance is used to adjust the current-sharing impedance without changing the equivalent output impedance, which can effectively reduce current-sharing errors. Finally, simulation and experimental results verify the structure and control method.