Courseware development for a laboratory class in power electronics

Abstract

This thesis introduces a new lab kit that is uniquely suited to teach power electronics: the Power NerdKit. The Power NerdKit is a self-contained prototyping system, which is easily incorporated into other systems such as an electric go-kart. Central to the kit is the card-rack prototyping area, where circuitry on PCB cards can be installed, interconnected, and tested. We present three prototyping PCB cards for use with the kit. Each of the cards has a common interconnection inter- face: up to five high current connections can be made via terminal lugs, and up to 26 low current connections can be made via card-edge connector. The first card provides solderless breadboard for constructing circuits and can connect with other cards through the standard interface. The second card is similar to the first, but is designed for circuits that must be soldered together. The last card, called the TriTotemII, implements three "totem-pole" circuits, which form the foundation of the converter topologies taught in the class. Finally the cards feature a unique method to attach oddly shaped devices using Unplated Through-hole Anchor Points. The lab exercises emphasize design.

(cont.) In Lab 1, the student: learns why switching circuits are useful; learns a few necessary control circuits; and builds a switching audio amplifier. In Lab 2, the student constructs a 1500W buck converter that drives an electric go-kart at variable speeds; they also design and build a 12W boosting power supply for a switching stereo amplifier of their construction. In Lab 3, the student designs and builds a high-voltage flyback converter and an electric fluorescent lamp ballast. Lastly, in Lab 4, the student explores how power electronics are used to drive induction and permanent magnet machines using a teaching motor specifically designed for this course.