Computer-Aided Design and Optimization of High-Efficiency LLC Series Resonant Converter
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机械设计制造及自动化专业英语翻译Mechanical Design, Manufacturing, and Automation Professional English TranslationIntroduction:Mechanical design, manufacturing, and automation are essential aspects of the engineering field. This specialized area involves the creation, production, and optimization of mechanical systems and components. To effectively communicate and collaborate with international partners, it is crucial to have a strong command of English in this field. This document aims to provide a comprehensive English translation for key terms and phrases commonly used in the mechanical design, manufacturing, and automation industry.1. Mechanical Design:Mechanical design refers to the process of creating and developing mechanical systems, machines, and devices. It involves various stages, including concept development, detailed design, and prototyping. Key terms related to mechanical design include:- Conceptualization: The initial phase of design, where ideas and concepts are generated and evaluated.- CAD (Computer-Aided Design): The use of computer software to create and modify designs.- 3D Modeling: The creation of a digital representation of a physical object or system.- Tolerance Analysis: The assessment of dimensional variations and their impact on performance and assembly.- Finite Element Analysis (FEA): A numerical method used to analyze the structural integrity and behavior of designs.- Design Optimization: The process of improving designs to achieve desired performance, efficiency, or cost-effectiveness.2. Manufacturing:Manufacturing involves the production of goods through various processes, such as machining, casting, forging, and assembly. Key terms related to manufacturing include:- CNC (Computer Numerical Control): The automation of machine tools through the use of computers to control machining operations.- Machining: The process of shaping or altering materials through cutting, drilling, milling, or grinding.- Casting: The manufacturing process of pouring molten material into a mold to obtain a desired shape.- Forging: The process of shaping metal through the application of localized compressive forces.- Assembly: The process of joining individual components to create a final product.3. Automation:Automation refers to the use of technology and control systems to operate and control machinery and processes with minimal human intervention. Key terms related to automation include:- PLC (Programmable Logic Controller): A digital computer used to control industrial processes and machines.- Robotics: The design, construction, and operation of robots to perform tasks autonomously or with human assistance.- Sensors: Devices that detect and measure physical or chemical properties and convert them into signals for control systems.- HMI (Human-Machine Interface): The interface that allows humans to interact with machines or systems.- SCADA (Supervisory Control and Data Acquisition): A system used to monitor and control industrial processes remotely.Conclusion:The mechanical design, manufacturing, and automation industry requires a deep understanding of technical terms and concepts. This English translation provides a comprehensive overview of key terms and phrases in this field. By familiarizing yourself with these terms, you will be better equipped to communicate effectively and collaborate with international partners in the mechanical design, manufacturing, and automation industry.。
creo新手练习题CREO(Computer-aided design(CAD)Reality With Excellence Optimization)是一款领先的三维CAD设计软件,广泛应用于工程设计和制造领域。
对于新手来说,熟悉并掌握CREO的操作技巧至关重要。
本文将为CREO新手提供一些练习题,帮助他们熟悉软件的功能和操作。
1. 绘制立方体第一个练习是绘制一个简单的立方体。
打开CREO软件,点击“新建”创建一个新的零部件。
选择“绘制”工具,然后选择“直线”工具绘制第一条边,再绘制相邻的边,最终完成立方体的绘制。
2. 创建3D模型在这个练习中,我们将创建一个简单的3D模型。
打开CREO软件,点击“新建”创建一个新的零部件。
选择“构建”工具,选择一个点作为基点,然后在不同方向上创建线段,连接起来形成一个形状复杂的3D模型。
3. 添加约束在这个练习中,我们将学习如何添加约束以确保模型的准确性。
打开CREO软件,创建一个新的零部件。
绘制一些线段形成一个形状,然后选择“约束”工具。
选择两个点,然后添加约束条件,比如垂直、水平等,以固定线段之间的相对位置。
4. 创建草图在这个练习中,我们将学习如何创建草图。
打开CREO软件,创建一个新的零部件。
选择“草图”工具,然后选择一个平面作为草图的基础平面。
利用线段、圆、弧等工具绘制形状,最后得到一个完整的草图。
5. 创建装配在这个练习中,我们将学习如何创建装配。
打开CREO软件,创建一个新的装配。
选择需要组装的零部件,并将它们放置在装配中的适当位置。
使用约束工具,将零件相对于其他零件进行位置固定,形成一个完整的装配。
6. 进行渲染在这个练习中,我们将学习如何给模型进行渲染,使其更加真实。
打开CREO软件,打开一个已有的模型。
点击“渲染”工具,选择适当的光源和材质,进行渲染操作。
预览渲染结果,根据需要进行调整,直至满意。
7. 进行运动分析在这个练习中,我们将学习如何进行运动分析以模拟物体的运动。
一. What is CAD, CAPP, CAM and CIMS, and briefly describe the relationship between them.1.CAD: computer-aided design ,it mainly refers to the use of the computer to complete the entire process of product design generally including CAD design and analysis of two aspects.2, CAPP: Computer Aided Process Planning, it refers to the use of computer technology to complete process planning of part machining.3.CAM: computer-aided manufacturing, it refers to the use of computers and numerical control equipment (such as CNC machine tools, machining centers, etc.) to manufacture parts.4.CAD / CAM: computer-aided design and computer-aided manufacturing referred to using the computer as the primary means to generate and use a variety of digital information and graphical information for the design and manufacture of the product.5.The relationship between CAD, CAPP, CAM: Generally speaking, CAD / CAM CAD / CAPP / CAM of. Referred to that contained in the CAD / CAM systems have CAPP. CAD system to produce parts (including geometricinformation and process manufacturing information, such as tolerance requirements, surface roughness, etc.). CAPP system to accept information from CAD, and the use of reasonable design, process design knowledge processing, optimized processing parameters and processing equipment. CAM CAD / CAPP / CAM system to accept the part information from the CAD and CAPP process planning and process parameters, after the processing of the CAM system to generate NC code, incoming numerical control equipment control equipment automatically processed6.CAD / CAM technology trends: integrated, intelligent, standardization, network-based, three-dimensional二:CADCAM1: Fill in the blanks (the big issue 20 small problem, every empty 1.5 points, a total of 30 points)(1) FMS is the abbreviation of Flexible Manufacturing System.(2) APT is an automatic programming tool (Automatically Programmed Tool) .(3) CAM is the abbreviation of computer aidedmanufacturing.(4) IMS is an abbreviation of the Intelligent Manufacturing Systems (Intelligent Manufacturing System.(5) RPM Rapid Prototyping / parts manufacturing (Rapid Prototyping / Parts Manufacturing abbreviation. (6) AM agile manufacturing Agile Manufacturing of abbreviations.(7) CAD functions can be grouped into geometric model, the four categories of engineering analysis, dynamic simulation and automatic drawing.(8) the engineering database for input and output, and management is required in the design process of the data used and generated by the pattern, documents, etc..(9) usually refers only to the narrow CAM NC program preparation, including the regulation of the tool path, the cutter location file generated simulation of the tool path and NC code generation.(10) The development of application software based on the the User programming language (UPL) supporting and CAD / CAM software system integrally has a good user interface, such enhancements may extend the functionof the CAD / CAM software system.(11) The application software can be automatic programming software, including identifying and processing of the source language software written by the CNC language (such as the APT language software) and a variety of CAD / CAM software.(12) to optimize the design including the optimization of the overall program the part structure optimization and optimization of process parameters.(13) CAD / CAM is a human-computer interaction process, from the shape of the products, ideas and programs, structural analysis process simulation system at any time to ensure the user to view, modify, intermediate results, real-time editing process.(14) modeling technique is the core of the CAM system, for the design and manufacture of the product to provide all the basic data and the original information, is the basis of the subsequent processing.(15) CAD / CAM system according to the three-dimensional model to calculate the geometric characteristics and physical characteristics of the corresponding objects.(16) CAD / CAM system with good information transmission management functions and information exchange process, to support the design and manufacture of the whole process of information transmission and exchange, and the transmission and sharing of information between multiple designers and design teams.(17) CIMS subsystem including management information systems, manufacturing automation systems and CAD / CAPP / CAM integrated system.(18) networking equipment necessary equipment, CAD / CAM systems set up its network equipment is composed of a computer network hubs, network cards, the transmission medium.(19) System software is responsible for managing hardware resources and software resources, for all users, it is a public computer software, including operating systems, compilers, graphics jack and jack standard.(20) Boolean operations, including pay and poor kinds of operations.2: Explain the following terms (the big issue of 6, atotal of 18 points)(1) parametric modeling: parametric modeling is to first establish the constraint relationship between the graphics and size parameters, and then use constraints to define and modify the geometry model. Size constraints and topological constraints reflect the factors to be considered in the design. Because the parameters of a set of parameters to maintain a certain relationship with these constraints, the initial design of the entity is natural to meet these constraints, enter the new parameter values will also keep these constraints and get a new geometric model.(2) plane contour sweeping method: planar contour sweeping method is closely combined with a two-dimensional system, commonly used in a way prismatic or rotary generated. Planar contour scanning method is translated in space by any plane contour a distance or around a fixed axis of rotation of will scan an entity. The plane contour scanning of the prerequisites is to have a closed planar contour (ie the plane contour scanning voxel). Closed planar contour is moved along one coordinate direction orrotation around a given axis.(3) Forming manufacturing technology: molding manufacturing technology is casting, plastic processing, connection, a collection of techniques of powder metallurgy unit. Prototyping and manufacturing technologies are manufacturing the workpiece blank, close to the shape of the part to be made directly workpiece precision molding technology. Plastic molding and grinding combined will replace most of the small parts machining.(4) Boolean operators: Boolean operators is the basis of geometric modeling technology, it is a set operation from Boolean algebra. Boolean operations voxel can be combined into complex shapes, the two objects combined to construct a new object. Boolean operations can facilitate the construction of complex geometric entities. Therefore, in the geometric modeling Boolean operation is very important. Boolean operators include cross (intersection), and (Union) (Difference) three operations.(5) contour milling: the tool contour inspection hierarchical processing of the workpiece, theperipheral contour finishing choose a method.The milling part contour to be considered to maximize the use of the climb milling processing methods, this can increase the surface roughness of parts and machining accuracy and reduce the Machine "flutter". To select reasonable into the retraction position, try to avoid along the part contour method to pause midway to cut and feed; into the retraction position is to be elected in a less important position; when the workpiece border open, in order to ensure processing surface quality, should be outside the boundaries of the workpiece into and retract.(6) virtual manufacturing: the virtual manufacturing is to achieve the essence of the actual manufacturing process on the computer, that computer simulation and virtual reality technology, group work together on the computer, product design, process planning, manufacturing, performance analysis, quality inspection and enterprise levels, process management and control products such as the nature of the manufacturing process in order to enhance the manufacturing process at all levels of decision-makingand control.(7)modification technology: modification technology, including the technology of heat treatment and surface engineering. The major trends is achieved through a variety of new precision heat treatment and composite processing the accurate performance parts, precision of shapes and sizes and a variety of special performance requirements of the surface (coating), while significantly reducing energy consumption and completely eliminate the pollution of the environment.(8) placed characteristics: Place features include hole features, round features, chamfer feature array characteristics. Placing characterized in that the parametric feature to change the location of the feature size and shape parameters, characteristic shape can be changed. Placed generally characterized by late in Part modeling was gradually added, because these features are designed to supplement and refine Part, such as the premature join, will shape the inconvenience.(9) feature-based modeling: feature-based modeling is usually characterized by the shape model the accuracyfeature model, material characteristics model, the shape of the feature model is the core and foundation of feature-based modeling. Is characterized by an integrated concept, as a carrier of information in the product development process, in addition to containing the part geometry and topology information, but also includes some non-geometric information required in the design and manufacturing process. Feature-based modeling is a built in solid modeling based on the use of the characteristics of the concept-oriented modeling method of the entire product design and manufacturing process design, it not only contains information related to the production, but also to describe the relationship between these information .(10) tool set sub-sequence method: Tool centralized sub-sequence method is used by the the tool division process, the site can be completed with the same knife finish machining parts, and then the second, third knife they can accomplish other parts. This can reduce the number of tool changes, compressed air-way time, reduce unnecessary positioning error.(11) geometric modeling: geometric modeling bygeometric elements such as point, line, surface, body, after geometric transformations such as translation, rotation and cross, and poor Boolean operations, resulting in a solid model. Geometric modeling technology as the basis of the CAD / CAM technology, wide range of applications in the field of mechanical engineering.(12) characterized in tree: a feature-based modeling process, the characteristics of 11 successively added to the model, the follow-up characteristic feature attached to the front, the front characteristics of the changes will affect the follow-up characteristics of the changes. In order to properly record the course of feature-based modeling, the use of the feature tree "concept, feature-based modeling process as a tree growing process, starting from the root (basic features), and gradually grow tree twigs (additional features). Part structure of different levels of complexity, the complexity of the feature tree type. Brief answer (the big 4, a total of 25 points)(1) CAD / CAM system (6)1. A variety of CAD / CAM systems basic human-computerinteraction (also known as man-machine dialogue) (1) 2. The operator according to the specific requirements of the instruction issued to the computer (1),3. Computer will be the result of the operation in the form of graphics or data displayed on the computer display (1)4. Operator via the input device to issue a new command to the computer (1).5. Computer according to the new instructions to complete the new instruction (1).6. The job information in the CAD / CAM generated continuously modify, exchange, access process. (2) (2) which aspects should pay attention to when the workpiece is being clampedShould maximize the use of modular fixture, but when the workpiece bulk, high precision, you can design special fixtures. (1)2 part positioning, clamping parts should be without prejudice to the measurement of the various parts of the processing, the replacement of the tool as well as important parts of the tool and the workpiece, tool and fixture collision phenomenon, in particular, should beavoided. (2)3 clamping force should seek close to the main points of support within the triangle formed by the points of support; should seek close to the cutting area, and rigid; Try not above the aperture processing, to reduce the warp. (2)4 parts clamping, positioning to consider the consistency of repeated installations, in order to reduce the time on the knife to improve the consistency of the same batch parts processing; generally the same batch of parts with the same positioning reference and the same clamping means. (2)(3) how to determine the point on the knife and tool change point (6)1. Knife point CNC machining starting point of the tool relative to the workpiece movement, the position of the tool in the workpiece coordinate system. (1)2. Determine the knife point of principle is: to facilitate the mathematical processing and simplify programming; easy alignment on the machine; to facilitate inspection process; processing errors caused by small. (2)3. Knife point can be set on the part fixture or machine, but must be part of the positioning reference coordinate dimensions, so as to determine the relationship between the machine coordinate system and workpiece coordinate system. (1)4. When you require a higher accuracy of the knife, the knife point should be selected on the part of the design basis or process basis. For parts positioning hole, the election center of the hole as the knife point. (1)5. Should be on the knife, the knife point coincide with the knife sites. Knife sites for end mills, end mill as the center of the underside of the head, the ball head center ball end mill for turning, boring tool is the tool tip for the drill bit to drill tip. (1)6. The tool change point should be determined according to the process content. In order to prevent the tool bumps workpiece is when the tool change, tool change point should be located in the outside of the part or fixture. (1)(4) the difference of the feature tree and the course number and contact (7)1. "Feature tree" and subsequent features characteristic attached to the front, the front characteristics of the changes will affect the follow-up characteristic changes. A complex parts by many characteristics, the characteristics of complex dependencies (2)2. Feature tree for parametric modeling system (2)3. History tree the variable modeling system using (2)4. Characteristics in addition to the "history tree" remain associated with the characteristics of the front, at the same time to establish contact with the system global coordinate system. The history tree also allows a number of parts merged together to construct a complex parts. The history tree clearly documented the design process, easy to modify, easy multiplayer co-design.(1)IV: Analysis answer the following questions (the big issue of small, a total of 27 points)(1) feature-based solid modeling method which is divided into several categories, its shape What are the steps (13)A modeling program planning: including thecharacteristics of the analysis part, the relationship between the analysis part features, the construction method of the analysis of the characteristics of the construction sequence and characteristics. (4)2 Create the basic characteristics of the basic features: the building blocks of a part. (3)3 to create additional features: add on additional features one by one according to the shape of program planning. (2)4 Edit to modify the characteristics of: any time in the process of feature-based modeling can be modified characteristics, including modifying the characteristics of the shape, size, location, or characterized by affiliation, or even delete constructed features. (3)5 generated drawings: 3D to 2D technologies interact to generate two-dimensional drawings. (2)(2) CNC machining process decision with which aspects and Description (14)1 Make sure the processing program. Determine the processing program should be considered a reasonable and economical use of CNC machine tools, and give fullplay to the functions of the CNC machine tools. (2) 2 fixture design and selection. Should pay particular attention to speedy completion of the positioning of the workpiece and clamping process, in order to reduce the auxiliary time. Using modular fixture, production preparation period is short, fixture parts can be used repeatedly, the effect of the economy. In addition, the fixture should be easy to install, easy to size relationship between the coordination of the workpiece and machine coordinate system.3 Select the feed path. Reasonable choice of the feed path for CNC machining is very important. Should consider the following aspects: as far as possible to shorten the feed path, to reduce idling knife trip, improve production efficiency; reasonable selection from the knife point, entry point and cut way to ensure a smooth cut, there is no impact; ensure the accuracy and surface of the machined parts roughness requirements; guarantee the security of the process, to avoid the interference of the surface of the tool and the non-processing; help simplify the numerical calculation, to reduce the number of block programmingworkload. (5)4 Select a reasonable tool. To select the tool should be based on the performance of the workpiece material, the processing capacity of the machine, the type of processing operations, cutting and other process-related factors, including the structure of the tool type, material grades and geometrical parameters. (3)5 to determine a reasonable cutting.。
表示计算机辅助工程的英文缩写Computer-Aided Engineering (CAE) is a term commonly used to refer to the application of computer software and tools in the field of engineering. It encompasses a wide range of disciplines, including mechanical, electrical, civil, and chemical engineering, among others. CAE plays a crucial role in the design, analysis, and optimization of various engineering systems and processes. In this article, we will explore the significance of CAE and its impact on the engineering industry.One of the key advantages of CAE is its ability to simulate and model complex engineering problems. By using advanced software and algorithms, engineers can create virtual prototypes and test them under different conditions. This allows for a more efficient and cost-effective design process, as it reduces the need for physical prototypes and extensive testing. Additionally, CAE enables engineers to identify potential issues and make necessary modifications before the actual production or construction phase, saving both time and resources.Another important aspect of CAE is its contribution to the analysis and optimization of engineering systems. Through the use of computational methods, engineers can evaluate the performance of various components and systems, such as stress analysis, fluid dynamics, and thermal management. This enables them to identify potential weaknesses or areas for improvement, leading to enhanced designs and increased efficiency. Moreover, CAE facilitates the exploration of different design alternatives and the evaluation of their impact on performance, allowing engineers to make informed decisions based on data-driven analysis.Furthermore, CAE plays a significant role in the field of manufacturing. It enables engineers to simulate and optimize manufacturing processes, such as casting, molding, and machining. By analyzing factors such as material properties, tooling, and process parameters, CAE helps in improving product quality, reducing production costs, and minimizing waste. It also aids in the identification of potential manufacturing issues, such as part distortion or tool wear, allowing for timely adjustments and improvements.In addition to design and analysis, CAE is also utilized in the field of virtual testing and validation. Engineers can simulate and evaluate the performance of products under various operating conditions, such as structural integrity, durability, and safety. This helps in ensuring that products meet the required standards and regulations before they are manufactured or deployed. Virtual testing also allows for the identification of potential failure modes and the optimization of product performance, leading to enhanced reliability and customer satisfaction.The use of CAE has revolutionized the engineering industry, providing engineers with powerful tools and capabilities to tackle complex problems. It has significantly reduced the time and cost associated with traditional design and testing methods, while improving overall product quality and performance. Moreover, CAE has enabled engineers to explore innovative design concepts and push the boundaries of engineering possibilities.In conclusion, Computer-Aided Engineering (CAE) is an essential component of modern engineering practices. Its ability to simulate, analyze, and optimize engineering systems has revolutionized the design and manufacturing processes. By leveraging advanced software andcomputational methods, engineers can enhance product performance, reduce costs, and improve overall efficiency. CAE has undoubtedly become an indispensable tool in the field of engineering, enabling engineers to push the boundaries of innovation and deliver cutting-edge solutions.。
Engineering Optimization and DesignEngineering optimization and design are crucial aspects of the engineering process, as they involve finding the best possible solution to a problem withinthe given constraints. This can include maximizing efficiency, minimizing cost, reducing waste, or improving performance. However, achieving optimization and design excellence often presents challenges and requires a deep understanding of the problem at hand, as well as the ability to think critically and creatively. In this discussion, we will explore the complexities of engineering optimization and design, considering various perspectives and potential solutions. One of the primary challenges in engineering optimization and design is the need to balance competing objectives. For example, in the design of a new aircraft, engineers may need to optimize for factors such as fuel efficiency, speed, and passenger comfort. However, these objectives are often interconnected, and improving one may come at the expense of another. This requires a careful and nuanced approach to optimization, considering trade-offs and compromises to find the best overall solution. This can be a difficult and time-consuming process, as it often involves iterative design and analysis to refine the solution. Another challenge in engineering optimization and design is the need to account for uncertainty and variability. In many engineering applications, the operating environment and conditions are not fully known or predictable. This can make it difficult to optimize a design for all possible scenarios, as there may be trade-offs between robustness and performance. Additionally, there may be variability in material properties, manufacturing processes, or other factors that can impact the performance of a design. Accounting for these uncertainties requires aprobabilistic approach to optimization, considering the likelihood of different outcomes and designing for resilience. In addition to technical challenges, there are also human and organizational factors that can impact engineering optimization and design. For example, engineers may face pressure to meet tight deadlines or cost targets, which can limit the time and resources available for optimization. There may also be conflicting priorities within an organization, with different stakeholders advocating for their own objectives. This can make it difficult to achieve consensus on the best approach to optimization and design, and may requirecompromise and negotiation to move forward. Additionally, there may be resistance to change or new ideas, particularly if they challenge established practices or beliefs. Despite these challenges, there are a variety of tools and techniques available to engineers to support optimization and design. For example, computer-aided design (CAD) software allows engineers to create and analyze virtual prototypes, enabling rapid iteration and exploration of design alternatives. Simulation and modeling tools can be used to predict the performance of a design under different conditions, helping to identify potential issues and opportunities for improvement. Additionally, optimization algorithms and techniques, such as genetic algorithms or simulated annealing, can be used to search for the best solution within a complex design space. Ultimately, achieving excellence in engineering optimization and design requires a combination of technical expertise, creativity, and collaboration. Engineers must have a deep understanding of the problem they are trying to solve, as well as the constraints and objectives that define the design space. They must also be willing to think critically and challenge assumptions, exploring new ideas and approaches to find innovative solutions. Collaboration with colleagues and stakeholders can also be valuable, bringing diverse perspectives and expertise to the table. By embracing these principles and leveraging the available tools and techniques, engineers can overcome the challenges of optimization and design, ultimately delivering better solutions for the world.。
AUTOMOBILE EDUCATION | 汽车教育时代汽车 汽车类专业《计算机辅助设计》课程思政教育的探索与实践程彩霞 高广慧黄河交通学院 河南省焦作市 454950摘 要: 文章阐述了《计算机辅助设计》课程融入思政元素的必要性,以应用型本科汽车类专业《计算机辅助设计》为例,研究该课程理论与实践思政教学体系的建设与实践途径,也为汽车类专业课课堂教学加强思想政治教育提供了方向和行动指南。
关键词:计算机辅助设计 思政 素质 实践1 引言无论学的是哪一门学科,均需要具有育人的作用,每一个学科要牢守自己的责任,开展有效的育人教育。
而《计算机辅助设计》课程专业性极强,所以在教育过程中一般只重视其实用性,却未能重要其起到的育人之用。
思政课程与高校培养高素质人才有着密切的关系,良好的思政课才能培养优秀的人才,让学生拥有良好的思想道德水平。
因此,在高校教学过程中,需要把思政课程融入至课堂设计过程,有效发掘《计算机辅助设计》课程当中的各种思政要素,充分发挥高校的思想和政治课程教育重要性和引导作用,促进高校学生的身心健康发展。
2 《计算机辅助设计》课程中融入思政元素的必要性在教育改革过程中,需要把专业课程与思政教育体制改革有效融合,特别是将民族的文化底蕴和社会主义为核心的价值观,实现潜移默化地将思政体制教育融于本专业的课程教学中。
实现思政教育潜移默化融入专业课程教学[2]。
2.1 可有效提高总体素质《计算机辅助设计》专业性非常强,所以在教学时,需要重视学生有关专业知识、绘图技巧等有关知识的传授。
但是,在教学过程中教师未能意识,作为一名制图人员,除了本身的素质专业过硬外,还要有良好的专业素养以及道德操守。
因此,在进行《计算机辅助设计》的课程教学过程中,需要融入德育观,将学科里的思政元素充分发挥,有效的将思政教学的各元素巧妙的与教学过程相结合。
只有这样的教学才能让学生在实践以及学习的过程中,构建良好的道德观,帮助学生提高总体素质。
附录1 英文原文Scope of CAD/CAMComputer-aided design is the use of computer systems to facilitate the creation, modification, analySIS, and optimization of a design. In this context the term computer system means a combination of hardware and software. Computer-aided manufacturing is the use of a computer system to plan, manage, and control the opemtion of a manufacturing plant. An appreciation of the scope of CAD/CAM can be obtained by considering the stages that must be completed in the design and manufacture of a product, as illustmted by the product cycle shown in Fig. 5 . 8. The inner loop of this figure in~ludes the various steps in the product cycle and the outer loop shows some of the functions of CAD/CAM superimposed on the product cycle .Based on market and customer requirements, a product is conceived, which may well be a modification of previous products. This product is then designed in detail, including any required design analysis, and drawings and parts lists are prepared. Subsequently, the various components and assemblies are planned for production, which involves the selection of sequences of processes and machine tools and the estimation of cycle times, together with the determination of process parameters, such as feeds and speedsCJJ. When the product is in production, scheduling and control of manufacture take place, and the order and timing of each manufacturing step for each component and assembly is detemnned to meet an overall manufacturing schedule. The actual manufacturing and control of product quality then takes place according to the schedule and the final products are delivered to the customers.Computer-based procedures have been or are being developed to facilitate each of these stages in the product cycle, and these are shown in the outer loop of Fig. 5 . 8. Computer-aided design and drafting techniques have been developed. These allow a geometric model of the product and its components to be created in the computer.This model can tlIen be analyzed using specialized software packages, such as those for finite element stress analysis, mechanisms design, and so on. Subsequently, dmwings and parts lists can be produced with computer-aided drafting software and plotters. Computer-aided process-planning systems, including the prepamtion of NC programs, are available that produce work plans, estimates, and manufacturing instructions automatically from geometric descriptions of the components and assemblies Cll•r'or scheduling and production control, large amounts of data and numerous relatively simple calculations must be carried out. One example is the determination of order quantities by subtmcting stock levels from forecasts of the number of items required during a particular manufacturing period®. Many commercial software packages are available for scheduling, inventory control, and shop floor control, including materials requirements planning (MRP) systems. At the shop- floor level computers are used extensively for the control and monitoring of individual machines.There is a difference in the time scale required for processing data and the issuing of instructions for these various applications of computers in the product cycle. For example, design and process-planning functions are carried out once for each new product and the time scale required is on the order of weeks to years for the competion of the task . Scheduling and production period cusually one week,throughout the year .at the machine-control level in-structions must be issued continually with a time scale of micro-or nanoseconds in many cases.One of the major objectives of CAM is the integration of the various activities in the product cycle into one unified system, in which data is transfened from one function to another automatically. This leads to theconcept of computer-integrated manufacture ( CIM), with the final objective being the "paperless" factory. Several developments have taken place, but no totally integrated CIM systems have yet been achieved. Since the design and process-planning functions are carned out once in the product cycle, these are the most suitable functions for integration. This integration is particularly desirable because thegeometric data generated during the design process is one of the basic inputs used by process plannipg when determining appropriate manufacturing sequences and work plans®. Consequently, various activities in desilSll and process planning can share a common design and manufacturing data base, as illustrated in Fig.5 .9. With such a system, geometric models of the products and components are created during the design process. This data is then accessed by various downstream activities, including N C programming, process planning, and robot programming. The programs and work plans generated by these activities are also added to the data base. Production control and inventory control programs can then access the work plans, time estimates, and parts lists (bill of materials file), in preparing the manufacturing schedules, for example.1 Computer-Aided DesignComputer-aided design, or CAD as it is more commonly known, has grown from a narrow activity and conceI;>t to a methodology of design activities that include a computer or group of computers used to assist in the analysis, development, and draw-ing of product components. The original CAD systems developed and used in industry could more realistically be classified as computer-aided drafting systems. However, the benefits, of using basic geometric information for structural analysis and planning for manufacturing were quickly recognized and included in many CAD systems. Today, as in the past, the basis for CAD is still the drafting features or interactive computer graphics (ICG) that these systems were originally designed to perform. However, the scope of these systems has taken on a new meaning.In general, there are four basic reasons for implementing CAD systems.1 .A reduction in design time. The total time required from inception of an idea to its complete specification can be reduced by an order of magnitude by using easily alterable geometric models. Design perturbations/ changes can be completed in minimal time. Whole scenarios of design possibilities can be constructed quickly.2. Improved product design. Because CAD systems allow the designer to alter the product without major redrav-ring with considerable time commitment, manyfinal designs can be constructed in a reasonable period of time. Similarly, these designs can be automatically analyzed for stlUCtural characteristics by using computer-aided engineering (CAE) software such as finite-element modeling (FEM) .3 .Improved information access. Because CAD drawings are stored in a large computer database, they can be accessed quickly and easily. Parts can be coded on the basis of geometric shape, and similar parts can be called up to assist in the design and specification of new parts. "Standard parts" can be employed whenever possible, rather than having to re-invent the wheel over and again.4. Manufacturing, data creation. With the advent of numerical control (NC) carne the need to automatically generate the tool path required for machining. Since the part geometry dictates the machining required, kno,,-ing the part shape can allow for (semi-)automatic part-prograrn preparation. CAD data can also be used for automated process planning.It is interesting to note that twenty years ago if a part of reasonable geometric and manufacturing sophistication was created, hundreds of design and drafting hours would be required. After the part was specified, marlufacture would begin. ll1is planning would normally require some minor design changes (back to the designer and draftsman), and might take as long as the original design process. Special tooling, fixturing, etc., might also be specified during the plarming for manufacture. In all, the entire process of product and process design could take several weeks or months. With today's CAD systems, designing (againg a rea.'\onably sophisticated component) and generating manufacturing plans, preparingpaIt programs and producing the pm is possible in days rather than weeks. Ingeneral, the tatal en!?ineering aI1d manufacturing time has been markedly using integrated CAD/CAM methodalogies.2 Computer- Aided lVIanufacturingThe scientific study of metal-cutting and autamatian techniques are pnxlucts af the twentieth centu ry. Two.pianeers of these techniques were Frederick Taylar and HenryFord. During tl1e early 1900s, the improving U. S. standard af living brought a new high in penlOnal wealth. 'Illemajar result wa<; the increased demand far durable goods. This increased demand meant that manufacturing cauld no. longer be treated as a blacksmith trade, aIld the use af scientific study was emplayed in manufacturing analysis. Taylarpianeered studies in "scientific ITlaI1agement" in which methods farproductian by both men and machines were studied. Taylar also conduetedmeatal-cutting experiments at the Midvale Steel Campai1y that lasted 26 yeaI"S and produced 400 tans af metal chips. The result af Taylar' s metal-cutting experiments was the develapment af the Taylar tool-life equation that is still used in industry today. This toollifeequatian is still the basis af detenniningecanamic metal cutting and has been used in adaptive can hulled machining.Henry Ford's contributions took a different turn from Taylor's. Ford refined and developed the use of assembly lines for the major component manufacturer of his automobile. Ford felt that every American family sh~d have an automobile, and if they could be manufactured inexpensively enough then every family would buy one. Several mechanisms were developed at Ford to accommodate assembly lines. The automation that Ford developed was built into the hardware, and Ford realized that significant demand was necessary to offset the, initial development and production costs of such systems.Although manufacturing industries continued to evolve, it was not until the 1950s that the next major development occurred. For some time, strides to reduce human involvement in manufacturing were being taken. Speciality machines using carns and other "hardwired" logic controllers had been developed. The U. S. Air Force recognized the development time required to produce this special equipment and that the time required to make only small sequence changes was excessive. As a result, the Air Force commissioned the Massachusetts Institute of Technology to demonstrate programmable or numerically controlled (NC) machines (also knO"\\l1 as "softwired" machines). With this first demonstration in 1952 came the beginning of a new era in manufacturing. Since then, digital computers have been used to produce input either in a directed manner to many NC machines, direct numericalcontrol (DNC), or in a more dedicated control sense, computer numerical control (CNC). Today, machine control languages such as APT (Automatic Programming Tool) have become the standard for creating tool control for NC machines.It is interesting to note that much of the evolution in manufacturing has come. as a response to particular changes during different periods. For instance, the technology that evolved in the nineteenth century brought with it the need for higher-precision machining (This resulted in the creation of many new machine tool;a more refined machine design, and new production processes. ). The early twentieth century became an era of prosperity and industrialization that created the demand necessary for mass-production techniques. In the 19?Os it was estimated that as the speed of an aircraft increased, the cost of manufacturing the aircraft (because of geometric complexity) increased proportionately with the speed. The result of this was the development of NC technology.A few tangential notes on this history include the following. As the volume of parts manufactured increases, the production cost for the parts decrease (this is generally known as "economy of scale"). Some of the change in production cost is due to fixed versus variable costs. For instance, if only a single part is to be produced (such as a space vehicle), all of the fixed costs for planning and design (both product and process) must be absorbed by the single item. If, however, several parts are produced, the fixed charges can be distributed over several parts. Changes in production cost, not reflected in this simple fixed-veIsus variable cost relationship, are usually the result of different manufacturing procedures -transfer-line techniques for high-volume items veISUS job-shop procedures for low-volume items.The U. S. Department of Commerce has pointed out that in the United States, 95 % of all products are produced in lots of size 50 or fewer. This indicates that althoughhigh-volume techniques are desirable from a consumer standpoint (lower cost), these techniques are not appopriate from a manufacturing standpoint (lower cost); the reason being the volume will not offset the setup expenses. The manufacturing al-ternative t6 produce those parts is through the use of flexible manufacturing systems (FMSs). These systems are nothing more than programmable job shops. However, amajor economic expense still exists before one can begin employing such systems more fully. TIlis obstacle is that a considerable setup (plan- ning ) expense is still required. The alternative to eliminate this expensive setup is through integration of computer-aided design and computer-aided manufacturing (CAD/CAM). In an integrated CAD/ CAM system, parts will be detailed using a CAD system. 'This system iIJ store the geometric information necessary to create process plans and generate the machine instructions necessary to control the machine tools. Some estimates suggest that this approach will reduce planning time for FMS parts by more than 95%.1中文翻译CAD/CAM的应用范围计算机辅助设计是利用计算机系统对某项设计进行创造、修改、分析、和优化。
生产制造管理中常用英文单词A/D/V Analysis/Development/Validation 分析/发展/验证AA Approve Architecture 审批体系ACD Actual Completion Date 实际完成日期ALBS Assembly Line Balance System 装配线平衡系统 ANDON 暗灯(安腾灯)AP Advanced Purchasing 提前采购API Advanced Product Information 先进的产品信息 APQP Advanced Product Quality Planning 先期产品质量策划 ATT Actual Tact Time 实际单件工时BIQ Building in Quality 制造质量BIW Body In White 白车身BOD Bill of Design 设计清单BOE Bill of Equipment 设备清单BOL Bill of Logistic 装载清单BOM Bill of Material 原料清单BOP Bill of Process 过程清单BPD Business Plant Deployment 业务计划实施CAD Computer-Aided Design 计算机辅助设计CAE Computer-Aided Engineering 计算机辅助工程(软件) CARE Customer Acceptance & Review Evaluation用户接受度和审查评估 CAS Concept Alternative Selection 概念可改变的选择 CIP Continue Improve Process 持续改进CIT Compartment Integration Team 隔间融合为组CKD Complete Knockdown 完全拆缷CMM Coordinate Measuring Machines 坐标测量仪CPV Cost per Vehicle 单车成本CR&W Controls/Robotics & Welding 控制/机器人技术和焊接 CS Contract Signing 合同签订CTD Cumulative Trauma Disadjust 累积性外伤失调CTS Component Technical Specification 零件技术规格CVIS Completed Vehicle Inspection Standards 整车检验标准 D/PFMEA Design/process failure mode & effects analysis设计/过程失效模式分析DAP Design Analysis Process 设计分析过程DES Design Center 设计中心DFA Design for Assembly 装配设计DOE Design Of Experiments 试验设计DOL Die Operation Line-Up 冲模业务排行DPV Defect per Vehicle 单车缺陷数DQV Design Quality Verification 设计质量验证DRE Design Release Engineer 设计发布工程师DRL Direct Run Loss 直行损失率DRR Direct Run Run 直行率DSC Decision Support Center 决策支持中心ECD Estimated Completion Date 计划完成日期EGM Engineering Group Manager 工程组经理ELPO Electrode position Primer 电极底漆ENG Engineering 工程技术、工程学EOA End of Acceleration 停止加速EPC&L Engineering Production Cntrol &Logistics 工程生产控制和后勤EQF Early Quality Feedback 早期质量反馈EWO Engineering Work Order 工程工作指令FA Final Approval 最终认可FE Functional Evaluation 功能评估FEDR Functional Evaluation Disposition Report 功能评估部署报告FFF Free Form Fabrication 自由形态制造FIN Financial 金融的FL 听FMEA Failure Mode and Effects Analysis 失效形式及结果分析 FPS Fixed Point Stop 定点停FTP File Transfer Protocol 文件传送协议FTQ First Time Quality 一次送检合格率GA General Assembly 总装GA Shop General Assembly Shop 总装车间Paint Shop 涂装车间Body Shop 车身车间Press Shop 冲压车间GCA Global Customer Audit 全球顾客评审GD&T Geometric Dimensioning & Tolerancing 几何尺寸及精度 GDS Global Delivery Survey 全球发运检查GM General Motors 通用汽车GMAP GM Asia Pacific 通用亚太GME General Motors Europe 通用汽车欧洲GMIO General Motors International Operations 通用汽车国际运作 GMIQ General Motors Initial Quality 通用汽车初始质量 GMPTG General Motors Powertrain Group 通用汽车动力组GMS Global Manufacturing System 通用全球制造系统GP General Procedure 通用程序GQTS Global Quality Tracking System 全球质量跟踪系统 GSB Global Strategy Board 全球战略部HVAC Heating, Ventilation ,and Air Conditioning 加热、通风及空调 I/P Instrument Panel 仪表板IC Initiate Charter 初始租约ICD Interface Control Document 界面控制文件IE Industrial Engineering 工业工程IEMA International Export Market Analysis 国际出口市场分析 ILRS Indirect Labor Reporting System 间接劳动报告系统 IO International Operations 国际业务IOM Inspection Operation Mathod 检验操作方法IOS Inspection Operation Summary 检验操作概要IPC International Product Center 国际产品中心 IPTV Incidents Per Thousand Vehicles 每千辆车的故障率 IQS Initial Quality Survey 初始质量调查IR Incident Report 事故报告ISP Integrated Scheduling Project 综合计划ITP Integrated Training Process 综合培训方法ITSD Interior Technical Specification Drawing 内部技术规范图IUVA International Uniform Vehicle Audit 国际统一车辆审核 JES Job Element Sheet 工作要素单JIS Job Issue Sheet 工作要素单JIT Just in Time 准时制JPH Job per hour 每小时工作量KCC Key Control Characteristics 关键控制特性KCDS Key Characteristics Designation System 关键特性标识系统KPC Key product Characteristic 关键产品特性LT Look at 看MFD Metal Fabrication Division 金属预制件区MFG Manufacturing Operations 制造过程MIC Marketing Information Center 市场信息中心MIE Manufacturing Integration Engineer 制造综合工程师 MKT Marketing 营销MLBS Material Labor Balance System 物化劳动平衡系统 MMSTS Manufacturing Major Subsystem TechnicalSpecifications 制造重要子系统技术说明书MNG Manufacturing Engineering 制造工程MPG Milford Proving Ground 试验场MPI Master Process Index 主程序索引MPL Master Parts List 主零件列表MPS Material Planning System 原料计划系统MRD Material Required Date 物料需求日期MSDS Material Safery Data Sheets 化学品安全数据单MSE Manufacturing System Engineer 制造系统工程MSS Market Segment Specification 市场分割规范MTBF Mean Time Between Failures 平均故障时间MTS Manufacturing Technical Specification 生产技术规范 MVSS Motor Vehicle Safety Standards 汽车发动机安全标准NAMA North American Market Analysis 北美市场分析NAO North American Operations 北美业务NAOC NAO Containerization NAO货柜运输NC Numerically Controlled 用数字控制NOA Notice of Authorization 授权书NSB NAO Strategy Board 北美业务部OED Organization and Employee Development 组织和员工发展 OSH Occupational Safety & Health 职业安全健康OSHA Occupational Safety & Health Act 职业安全与健康法案 OSHMS Occupational Safety & Health Management System 职业安全健康管理体系OSHS Occupational Safety & Health Standards 职业安全标准 PA Production Achievement 生产结果PAA Product Action Authorization 产品临时授权PAC Performance Assessment Committee 绩效评估委员会 PACE Program Assessment and Control Environment 项目评估和控制条件PAD Product Assembly Document 产品装配文件PARTS Part Readiness Tracking System 零件准备跟踪系统PC Problem Communication 问题信息PCL Production Control and Logistics 生产控制和支持PCM Process Control Manager 工艺控制负责人PCR Problem Communication Report 问题交流报告PDC Portfolio Development Center 证券发展中心PDM Product Data Management 产品资料管理PDS Product Description System 产品说明系统PDT Product Development Team 产品发展小组PED Production Engineering Department 产品工程部PEP Product Evaluation Program 产品评估程序PER Personnel 人员PET Program Execution Team 项目执行小组PGM Program Management 项目管理PI People Involement 人员参与PIMREP Project Incident Monitoring and ResolutionProcess 事故方案跟踪和解决过程PLP Production Launch Process 生产启动程序PMI Process Modeling Integration 加工建模一体化PMM Program Manufacturing Manager 项目制造经理PMR Product Manufacturability Requirements 产品制造能要求 PMT Product Management Team 产品车管理小组POMS Production Order Management System 产品指令管理小组 POP Point of Purchase 采购点PP Push - Pull 推拉Production Part Approval Process 生产零部件批准程序PPE 个人防护用品PPH Problems Per Hundred 百辆车缺陷数PPM Problems Per Million 百万辆车缺陷数PPS Practical Problem Solving 实际问题解决PR Performance Review 绩效评估PR/R Problem Reporting and Resolution 问题报告和解决 PRTS Problem Resolution and Tracking System 问题解决跟踪系统PSC Portfolio Strategy Council 部长职务策略委员会PST Plant Support Team 工厂支持小组PTO Primary Tryout 第一次试验PTR Production Trial Run 生产试运行PUR Purchasing 采购PVD Production Vehicle Development 生产汽车发展PVM Programmable Vehicle Model 可设计的汽车模型QA Quality Audit 质量评审QAP Quality Assessment Process 质量评估过程QBC Quality Build Concern 质量体系构建关系QC Quality Characteristic 质量特性QCOS Quality Control Operation Sheets 质量风险控制QE Quality Engineer 质量工程师QET Quality Engineering Team 质量工程小组QFD Quality Function Deployment 质量功能配置QRD Quality, Reliability,andDurability 质量、可靠性和耐久力QS Quality System 质量体系QUA Quality 质量RC Review Charter 评估特许RCD Required Completion Date 必须完成日期RFQ Request For Quotation 报价请求RGM Reliability Growth Management 可靠性增长小组RONA Return on Net Assets 净资产评估RPO Regular Production Option 正式产品选项RQA Routing Quality Assessment 程序安排质量评定RT&TM Rigorous Tracking and Throughout Managment 严格跟踪和全程管理SDC Strategic Decision Center 战略决策中心SF Styling Freeze 造型冻结SIL Single Issue List 单一问题清单SIP Stansardized Inspection Process 标准化检验过程SIU Summing It All Up 电子求和结束SL System Layouts 系统规划SLT Short Leading Team 缩短制造周期SMARTSMBP Synchronous Math-Based Process 理论同步过程SME Subject Matter Expert 主题专家SMT Systems Management Team 系统管理小组SNR 坏路实验Start of Production 生产启动Safe Operating Practice 安全操作规程SOR Statement of Requirements 技术要求SOS Standardization Operation Sheet 标准化工作操作单 SOW Statement of Work 工作说明SPA Shipping Priority Audit 发运优先级审计SPC Statistical Process Control 统计过程控制SPE Surface and Prototype Engineering 表面及原型工程 SPO Service Parts Operations 配件组织SPT Single Point Team 专一任务小组SQA Supplier Quality Assurance 供应商质量保证(供应商现场工程师)SQC Supplier Quality Control 供方质量控制SQD Supplier Quality Development 供应方质量开发SQE Supplier Quality Engineer 供方质量工程师SQIP Supplier Quality Improvement Process 供应商质量改进程序SSF Start of System Fill 系统填充SSLT Subsystem Leadership Team 子系统领导组SSTS Subsystem Technical Specification 技术参数子系统 STD Standardization 标准化STO Secondary Tryout 二级试验SUI 安全作业指导书SUW Standard Unit of Work 标准工作单位SWE Simulated Work Environment 模拟工作环境TAG Timing Analysis Group 定时分析组TBD To Be Determined 下决定TCS Traction Control System 牵引控制系统TDC Technology Development Centre 技术中心TDMF Text Data Management Facility 文本数据管理设备TG Tooling 工具TIMS Test Incident Management System 试验事件管理系统 TIR Test Incident Report 试验事件报告TMIE Total Manufacturing Integration Engineer 总的制造综合工程TOE Total Ownership Experience 总的物主体验TPM Total Production Maintenance 全员生产维护TSM Trade Study Methodology 贸易研究方法TT Tact Time 单件工时TVDE Total Vehicle Dimensional Engineer 整车外型尺寸工程师TVIE Total Vehicle Integration Engineer 整车综合工程师 TWS Tire and Wheel System 轮胎和车轮系统UAW United Auto Workers 班组UCL Uniform Criteria List 统一的标准表UDR Unverified Data Release 未经核对的资料发布UPC Uniform Parts Classification 统一零件分级VAE Vehicle Assembly Engineer 车辆装配工程师VAPIR Vehicle & Progress Integration Review Team 汽车发展综合评审小组VASTD Vehicle Assembly Standard Time Data 汽车数据标准时间数据VCD Vehicle Chief Designer 汽车首席设计师VCE Vehicle Chief Engineer 汽车总工程师VCRI Validation Cross-Reference Index 确认交叉引用索引 VDP Vehicle Development Process 汽车发展过程VDPP Vehicle Development Production Process 汽车发展生产过程VDR Verified Data Release 核实数据发布VDS Vehicle Description Summary 汽车描述概要VDT Vehicle Development Team 汽车发展组VDTO Vehicle Development Technical Operations 汽车发展技术工作VEC Vehicle Engineering Center 汽车工程中心VIE Vehicle Integration Engineer 汽车综合工程师VIN Vehicle Identification Number 车辆识别代码VIS Vehicle Information System 汽车信息系统VLE Vehicle Line Executive 总装线主管VLM Vehicle Launch Manager 汽车创办经理VMRR Vehicle and Manufacturing Requirements Review 汽车制造必要条件评审VOC Voice of Customer 顾客的意见VOD Voice of Design 设计意见VS Validation Station 确认站VSAS Vehicle Synthesis,Analysis,and Simulation 汽车综合、分析和仿真VSE Vehicle System Engineer 汽车系统工程师VTS Vehicle Technical Specification 汽车技术说明书WBBA Worldwide Benchmarking and Business Analysis 全球基准和商业分析WOT Wide Open Throttle 压制广泛开放WPO Work Place Organization 工作场地布置WWP Worldwide Purchasing 全球采购COMMWIP Correction 纠错浪费Overproduction 过量生产浪费Material Flow 过度物料移动浪费Motion 过度移动浪费Waiting 等待浪费Inventory 过度库存浪费Processing 过度加工浪费什么是TPM(Total Productive Maintenance)?Description:TPM是Total Productive Maintenance 第一个字母的,本意是"全员参与的生产保全",也翻译为"全员维护",即通过员工素质与设备效率的提高,使企业的体质得到根本改善。
第28卷 第2期2021年2月仪器仪表用户INSTRUMENTATIONVol.282021 No.2基于Eplan二次开发的电气辅助设计工具集的设计与实现张 旭,姚 璋,袁友汶,黄 鹏(中国核动力研究设计院 核反应堆系统设计技术重点实验室,成都 610213)摘 要:对于DCS 等规模较为庞大的仪控系统,在进行工程硬件设计时,工程设计软件的作用极为重要。
Eplan 软件作为成熟的计算机辅助工程软件,提供了二次开发接口便于用户根据实际需要进行针对性开发。
本文基于Eplan 软件在DCS 电气设计过程中的应用,进行了软件的二次开发,针对提高设计过程中的便利性、容错性的目的,设计了一系列辅助设计工具,有效地提高了设计效率和质量。
关键词:Eplan ;二次开发;电气设计中图分类号:TM76 文献标志码:ADesign and Implementation of Electrical Aided Design ToolsBased on Eplan Secondary DevelopmentZhang Xu ,Yao Zhang ,Yuan Youwen ,Huang Peng(Science and Technology on Reactor System Design Technology Laboratory, Nuclear Power Institute of China,Cheng-du,610213,China)Abstract:For the large scale instrument and control system such as DCS, the role of engineering design software is very impor-tant in hardware design. As a mature computer-aided engineering software, Eplan provides a secondary development interface for users to develop according to their actual needs. Based on the application of Eplan software in the design process of DCS electric, this paper carries out the secondary development of the software, and designs a series of auxiliary design tools for the purpose of improving the convenience and fault tolerance in the design process, which effectively improves the design efficiency and quality.Key words:Eplan;secondary development;electrical designDOI:10.3969/j.issn.1671-1041.2021.02.014文章编号:1671-1041(2021)02-0048-050 引言随着电气设计行业的发展,计算机软件在现代电气产品的设计制造过程中的作用越来越大。
Computer-Aided Design and Optimization of High-Efficiency LLC Series Resonant Converter Ruiyang Yu,Godwin Kwun Yuan Ho,Bryan Man Hay Pong,Senior Member,IEEE,Bingo Wing-Kuen Ling,Senior Member,IEEE,and James Lam,Senior Member,IEEEAbstract—High conversion efficiency is desired in switch mode power supply puter-aided design optimization is emerging as a promising way to design power converters.In this work a systematic optimization procedure is proposed to optimize LLC series resonant converter full load efficiency.A mode solver technique is proposed to handle LLC converter steady-state solu-tions.The mode solver utilizes numerical nonlinear programming techniques to solve LLC-state equations and determine operation mode.Loss models are provided to calculate total component losses using the current and voltage information derived from the mode solver.The calculated efficiency serves as the objective function to optimize the converter efficiency.A prototype300-W400-V to12-V LLC converter is built using the optimization results.Details of design variables,boundaries,equality/inequality constraints,and loss distributions are given.An experimental full-load efficiency of97.07%is achieved compared to a calculated97.4%efficiency. The proposed optimization procedure is an effective way to design high-efficiency LLC converters.Index Terms—Computer-aided design,efficiency,LLC resonant converter,optimization,power converter.N OMENCLATUREa,b,c Curvefitting factor.a D F,b D F Curvefitting factor.A e Effective cross-sectional area of transformer.A e Lr Effective cross-sectional area of resonantinductor.b xl Lower bound vector of design variables.b xu Upper bound vector of design variables.B m X F Peak-to-peak swing of transformerfluxdensity.ΔB m X F Amplitude of transformerflux density swing.ΔB m Lr Amplitude of resonant inductorflux densityswing.C r Value of resonant capacitor.Manuscript received June22,2011;revised August26,2011and October 12,2011;accepted November23,2011.Date of current version April3,2012. Recommended for publication by Associate Editor D.Xu.R.Yu,G.K.Y.Ho,and B.M.H.Pong are with the Department of Electrical and Electronic Engineering,The University of Hong Kong,Hong Kong(e-mail: yry721@eee.hku.hk;godwinho@;mhp@eee.hku.hk).B.W.-K.Ling is with the School of Engineering,University of Lincoln, Lincolnshire,LN67TS,U.K.(e-mail:wling@).m is with the Department of Mechanical Engineering,The University of Hong Kong,Hong Kong(e-mail:m@hku.hk).Color versions of one or more of thefigures in this paper are available online at .Digital Object Identifier10.1109/TPEL.2011.2179562d AWG Diameter of AWG wire in transformerprimary winding.d Lr AWG Diameter of AWG wire in resonant inductorwinding.D F Dissipation factor.E offTurn-off energy consumed by primaryMOSFET.f Frequency.f r Resonant frequency(L r C r).f s Switching frequency.F Normalized frequency.F R Ratio of AC–DC resistance.F R pri Transformer primary side F R.F R sec Transformer secondary side F R.F Rn Lr Resonant inductor F Rn.h foil Thickness of foils in transformer secondarywinding.i Lr Resonant inductor current.I base Base current for normalization.I n pri n th harmonic component of primary RMScurrent.I n sec n th harmonic component of secondary RMScurrent.I Lr MAX Maximum resonant inductor current.I offTurn-off current of primary MOSFET.I rip in Input ripple current.I rip out Output ripple current.I RMS pri Primary side RMS current.I RMS sec Secondary side RMS current.j Lr Normalized resonant inductor current.j Lm Normalized magnetizing current.j out Normalized output current.j rec Normalized secondary rectified current.k Steinmetz coefficient.k1Ratio of two resonant frequencies.k offRatio of turn-off energy and turn-off voltage. L r Resonant inductor value.L m Nagnetizing inductor value.m1,m2Normalized input/output voltage.m c Normalized resonant capacitor voltage.m Lr Normalized resonant inductor voltage.m m Normalized transformer voltage.m m2Normalized transformer voltage(modeindicator).M Normalized conversion ratio.n Order of harmonic frequency.n C in Number of input capacitor parallelled.0885-8993/$26.00©2011IEEEn C out Number of output capacitor parallelled.n layer Number of layers in transformer primarywinding.n Lr Number of turns in resonant inductor.n Lr layer Number of layers in resonant inductor.n sample Number of samples in each switching cycle. n p Number of transformer primary turns.n s Number of transformer secondary turns.p Number of layers in magnetic componentwinding.P cd pri Conduction loss of primary MOSFET.P cd S R Conduction loss of synchronous rectifier.P cu X F pri Copper loss of transformer primary side.P cu X F sec Copper loss of transformer secondary side. P cu Lr Copper loss of resonant inductor.P core X F Core loss of transformer.P core Lr Core loss of resonant inductor.P C r Loss of resonant capacitor.P C in Loss of input capacitor.P C out Loss of output capacitor.P g S R Gate-drive loss of synchronous rectifier.P g pri Gate-drive loss of primary MOSFET.P loss Sum of all losses.P out Output power.P sw pri Loss of primary MOSFET.P sw S R Switching-loss of synchronous rectifier.Q g pri Gate-drive charge of power MOSFET.Q g S R Gate-drive charge of secondary SR.Q oss S R Output capacitance charge of secondary SR. r L Normalized value of output load.R C r ESR of resonant capacitor.R ds pri On-state resistance of primary MOSFET.R ds S R On-state resistance of synchronous rectifier. R L Value of output load.R Lr DC resistance of resonant inductor.R X F pri Transformer DC resistance of the primaryside.R X F sec Transformer DC resistance of the secondaryside.t Time.v c V oltage of resonant capacitor.v Lm V oltage of magnetizing inductor.V1Input voltage of LLC equivalent circuit.V2Output voltage of LLC equivalent circuit.V base Base voltage in normalization.V g pri Gate-drive voltage of primary MOSFET.V g S R Gate-drive voltage of synchronous rectifier. V e Lr V olume of inductor core.V e X F V olume of transformer core.V in Input voltage.V out Output voltage.x Vector of design variables.Z base Base impedance.α,βNormalized angles.αcore,βcore Steinmetz coefficients.γNormalized half period of switching cycle.θNormalized angle(time based).λRatio of L r/L m.δ(n)Skin depth of n th harmonic frequency.ρcu Electrical resistivity of copper.μ0Vacuum permeability.ΩOptimization constraint set.ω0Resonant frequency(L r C r).ω1Resonant frequency(L r+L M C r).I.I NTRODUCTIONE NERGY efficiency is a hot topic that has drawn the atten-tion of researchers and engineers for decades.Numerous research works have focused on improving power converter effiputer-aided design optimization is one of the meth-ods used to achieve high-energy conversion efficiency,and it has been applied widely in conventional PWM converter design. Early research work[1]utilized the sequential unconstrained minimization technique(SUMT)or the augmented Lagrangian (ALAG)penalty function technique to optimize the converter mass.A practical converter optimization approach was devel-oped in[2]for industrial applications,which utilized the nonlin-ear optimization program to optimize converter design.Design optimization of interleaved converter for automobile applica-tions was investigated in[3].A Monte Carlo searching method was applied to handle a large number of design variables.Fuel cell system mass was minimized in[4]under a certain dura-tion constraint.The Pareto-front of power converter multiobject optimization was investigated by[5].The Pareto-front of con-verter volume and efficiency were obtained,which means no further efficiency improvement can be achieved under certain constraints,such as converter volume or mass.Converter vol-ume and efficiency were included in the weighted objective function to determine the degree of optimized efficiency or vol-ume.The Pareto-front curve of power density versus efficiency showed that the optimized efficiency was limited by a certain volume constraint.A similar optimization approach was applied to phase-shift PWM converter design in[6]to achieve99%ef-ficiency.LLC series resonant converter is emerging to meet the high-efficiency requirements of offline converter and it is be-coming increasingly popular in industrial applications.It has zero-voltage switching(ZVS)at primary side and zero-current switching(ZCS)at secondary side.Design methodology of1-MHz1-kW LLC converter was investigated in[7].Details of design procedure were presented in a digital control LLC con-verter[8].The LLC converter efficiency can be further im-proved by using synchronous rectifiers[9]–[11].Actually,it is more sensible to design and optimize the LLC converter and synchronous rectifiers as an entire system.Adaptive control methodology was proposed to improve the performance of LLC converter[12].The application of LLC converter in photovoltaic (PV)system was developed in[13].The advantage of high effi-ciency from light load to full load shows performance improve-ments of the entire PV system.Design procedures for wide range LLC converter and dead-time of LLC converter were presented in[14],[15],respectively.YU et al.:COMPUTER-AIDED DESIGN AND OPTIMIZATION OF HIGH-EFFICIENCY LLC SERIES RESONANT CONVERTER3245Fig.1.Half-bridge LLC series resonant DC/DC converter.So far,there is minimal work on the optimization of LLC converter.The optimization of LLC converter is more difficult than conventional PWM converters.This is because of the fol-lowing reasons:First,there are multiple modes of operations; each mode has different resonant characteristics.Second,the nonlinear behavior of LLC converter does not have closed-form solutions.One of the conventional methods used to predict LLC op-eration behavior is the fundamental harmonic approximation method[16].However,this method only considers the fun-damental frequency harmonic and produces errors when the switching frequency is not at resonant frequency.An improved LLC model was proposed in[17]to present more accurate wave-forms.The key equations were solved by numerical method, but this LLC model still assumed that the resonant current is sinusoidal.The steady-state solutions based on state-variable equation were developed in[18].This method can accurately predict LLC resonant behaviors.However,the nonlinear equa-tions do not have closed-form solutions.With the development of numerical computational techniques,the present research work utilizes nonlinear programming techniques to solve LLC converter steady-state equations.A mode solver is proposed to accurately predict LLC resonant behaviors.Such mode solver is a numerical procedure that considers LLC resonances at dif-ferent modes.Hence,the proposed mode solver is suitable for handling LLC design variables.Loss models are presented to predict converter losses that serve as the objective function to optimize LLC efficiency.A prototype400V to12V/25A LLC converter is built to verify optimization results.The measured efficiency of optimized LLC converter is97.07%at full load.II.LLC C ONVERTER M ODELSA.LLC Mode SolverA mode solver is proposed to compute the multiple-mode steady-state operation of the LLC converter.The half-bridge LLC converter topology is shown in Fig.1.There are two res-onant inductors and a resonant capacitor in the resonant tank. Hence,the name LLC represents these three resonant elements. Power MOSFETs are applied as the half-bridge switches,which are operated in complementary manner with nearly50%duty. Output voltage is regulated by variable frequency control.A dead-time is applied during the transition of switching to achieve zero voltage switching and to avoid cross conduction from high-side to low-side switches.The proposed LLC mode solver serves as a function block in the main optimization procedure.The input variables of the LLC steady-state solver are the values of resonant parameters,such as L r,C r,and L m and the excitations,such as the switching frequency,load,and input/output voltage.The state equations are solved numerically and the output of this function block are vectors containing particular waveform information of current and voltage.The LLC converter has several modes of opera-tion.These modes include the continuous conduction mode be-low or above resonance,discontinuous conduction mode below or above resonance,and cut-off mode.Continuous conduction mode is defined as a state in which the secondary diode con-ducts throughout the switching cycle.Discontinuous conduction mode is defined as the state in which secondary diode has cer-tain periods not conducting.The mode solver presented can tackle different modes,which are determined by the nonlinear relationship of the switching frequency,load,and input/output voltage.The detailed procedures of the LLC mode solver are in Fig.2.B.NormalizationThe solver procedures start with normalization,as shown in Fig.2(a1)and(a2).The resonant characteristics of the tank circuit are normalized for the sake of uniformity.We useω0and ω1to denote the two resonant frequenciesω0=1√L r C r=2πf r,ω1=1(L r+L m)C r.(1) The operation angleθis given byθ=ω0t.(2) Denote F the ratio of two frequenciesF=f sf r.(3) A half period of switching cycleγis defined byγ=ω02f s=πF.(4) The conversion ratio M is defined asM=V2V1.(5) We define some normalized parameters in the following:V base=V2=n pn sV out,m2=V2V base=1(6) m1=1M(7)Z base=L rC r(8)I base=V baseZ base(9) where V base is defined as the V2so that m2is normalized to unity,and m1is the normalized input voltage.The base impedance Z base and base current I base are given by(8)and(9), respectively.3246IEEE TRANSACTIONS ON POWER ELECTRONICS,VOL.27,NO.7,JULY2012Fig.2.Flow chart of LLC mode solver.The normalized voltage on resonant capacitor m c (θ)and normalized current through resonant inductor j Lr (θ)are,respectively,given bym c (θ)=v c (θω0)V base (10)j Lr (θ)=i Lr (θω0)I base.(11)Similar expressions are applied to m m (θ),m m 2(θ),m Lr (θ)j Lm (θ)and j out .The ratio of two resonant inductance λand the ratio of two resonant frequencies k 1are,respectively,given byλ=L rL m =m Lr (θ)m m (θ)(12)k 1=ω1ω0.(13)The normalized output load resistance r L is defined asr L =n 2p R Ln 2s Z base.(14)C.Operation Below Resonant Frequency1)Discontinuous Conduction Mode Below Resonance:If F <1,the LLC is assumed to operate in discontinuous con-duction mode below resonance (DCMB)first,as shown in Fig.2(a1).DCMB is one of the popular designed operation modes.In DCMB mode,the LLC converter voltage conversion ratio M is larger than unity (M >1).Typical waveforms in DCMB mode are shown in Fig.3(b).The equivalent circuit of DCMB mode in θ∈[0,α)is shown in Fig.4(b).The dead-time transition is ignored for simplified analyses.The state equations are given by (15)θ∈[0,α)⎧⎪⎪⎪⎪⎪⎨⎪⎪⎪⎪⎪⎩m c (θ)=[m c (0)−1M+1]cos(θ)+j Lr (0)sin(θ)+1M −1(15a)m m (θ)=1(15b)j Lr (θ)=[−m c (0)+1M −1]sin(θ)+j Lr (0)cos(θ)(15c)j Lm (θ)=j Lm (0)+λθ.(15d)YU et al.:COMPUTER-AIDED DESIGN AND OPTIMIZATION OF HIGH-EFFICIENCY LLC SERIES RESONANT CONVERTER3247Fig.3.LLC operation modes.3248IEEE TRANSACTIONS ON POWER ELECTRONICS,VOL.27,NO.7,JULY2012Fig.4.Equivalent circuits of LLC converter.The equivalent circuit in θ∈[α,γ)is shown in Fig.4(c).The state equations are given by (16)θ∈[α,γ)⎧⎪⎪⎪⎪⎪⎪⎪⎪⎪⎨⎪⎪⎪⎪⎪⎪⎪⎪⎪⎩m c (θ)=[m c (α)−1M ]cos[k 1(θ−α)]+j L r (α)k 1sin[k 1(θ−α)]+1M (16a)m m (θ)={[−m c (α)+1M]cos[k 1(θ−α)]−j L r (α)k 1sin[k 1(θ−α)]}/(1+λ)(16b)j Lr (θ)=[−m c (α)+1M ]k 1sin[k 1(θ−α)]+j Lr(α)cos[k 1(θ−α)](16c)j Lm (θ)=j Lr (θ).(16d)The average output current j out is given byj out =1γ γ0|j Lr (θ)−j Lm (θ)|dθ=1γ α[j Lr (θ)−j Lm (θ)]dθ=1γ−m c (0)+1M−1 (1−cos α)+j Lr (0)sin α−j Lr (0)α−12λα2.(17)The steady-state solution in DCMB [j Lr (0),m c (0),α,M ]can be solved by ⎧⎪⎨⎪⎩m c (0)+m c (γ)=0(18a)j Lr (0)+j Lr (γ)=0(18b)j Lr (α)−j Lm (α)=0(18c)j out r L −1=0.(18d)These four equations become the basis of the solver,andwhich adequately describe the waveforms of the resonant oper-ation.The initial condition m c (0)is equal to −m c (γ),as shown in Fig.3(b),given by (18a).The same reasoning can be applied to j Lr (0)and −j Lr (γ)in (18b).The diode stops conducting at an-gle α,where the resonant current equals to the magnetizing cur-rent.Hence,(18c)is formulated that j Lr (α)=j Lm (α).Finally,the unity output voltage is equal to j out r L ,given by (18d).These four equations have four unknowns [j Lr (0),m c (0),α,M ].Two unknowns are the normalized boundary value of resonant induc-tor current j Lr (0)and resonant capacitor voltage m c (0).The third unknown is the normalized time αthat the secondary diodestops conducting.The fourth unknown is the conversion ratio M .Since these unknowns do not have the analytical closed-form solution,the equations are solved by MATLAB function fsolve (x ),which is a numerical-based search function.After solving the above four equations,the following proce-dures are carried out to validate the assumption of DCMB.At the time when j Lr (θ)=j Lm (θ)(the moment θ=0or interval θ∈[α,γ]in DCMB),the voltage on L m determines whether the diodes start to conduct or not.A mode indicator m m 2(θ)is defined as the normalized voltage on L m ,based on the equiv-alent circuit Fig.4(c),when θ=0or θ∈[α,γ].According to Kirchhoff’s V oltage Law,we obtainm Lr (θ)+m m 2(θ)+m c (θ)=m 1.(19)The solution of m m 2(θ)can be derived by inserting (7)and (12)into (19).To simplify the analyses,we only consider the instants 0and γm m 2(θ)=−m c (θ)+1M1+λ|θ=0,γ.(20)(θ=0):If |m m 2(0)≥1|(the output voltage is normalized to 1),the secondary diode conducts and clamps the m m (0)to 1(DCMB true).Otherwise,if |m m 2(0)|<1,the secondary diode is OFF and it is no longer DCMB (DCMB false)but in another mode,discontinuous conduction mode above and below resonance (DCMAB),as shown in Fig.2(c1)and Fig.3(c).Since the LLC converter is assumed operating at DCMB at this moment,DCMAB should be considered later.(θ=γ):At the end of DCMB first half cycle γ,if |m m 2(γ)|≤1,diode is OFF (DCMB true).Otherwise,if |m m 2(γ)|>1,the assumption of DCMB is violated (DCMB false).Summaries are listed as below:Flow chart Fig.2(b1)shows,if |m m 2(0)|≥1and |m m 2(γ)|≤1,the assumption of DCMB is true.If |m m 2(0)|<1and |m m 2(γ)|<1,the assumption of DCMB is false then LLC converter is assumed to operate at DCMAB,as shown in Fig.2(c1).If |m m 2(0)|>1and |m m 2(γ)|>1,the assumption of DCMB is false and then LLC converter is assumed to oper-ate at DCMB2,as shown in Fig.2(d1).YU et al.:COMPUTER-AIDED DESIGN AND OPTIMIZATION OF HIGH-EFFICIENCY LLC SERIES RESONANT CONVERTER3249 2)Discontinuous Conduction Mode Above or Below Reso-nance:Flow chart Fig.2(c1)shows that the converter may op-erate at DCMAB.Procedures to solve DCMAB are presentedlater.The secondary diodes do not conduct inθ∈[0,α)or[β,γ)when the LLC converter operates at DCMAB,as shownin Fig.3(c).The equivalent circuit in DCMAB modeθ∈[0,α)and[β,γ)is the circuit(c)of Fig.4.The equivalent circuit inθ∈[α,β)is the circuit(a)of Fig.4.Five equations are formu-lated to solve DCMAB given by⎧⎪⎪⎪⎨⎪⎪⎪⎩m c(0)+m c(γ)=0(21a) j Lr(0)+j Lr(γ)=0(21b) j Lr(α)−j Lm(α)=0(21c) j Lr(β)−j Lm(β)=0(21d) j out r L−1=0.(21e)Similar to the procedure in DCMB equivalent circuit,the mode indicator m m2(0)and m m2(γ)can be calculated by(20). The assumption of DCMAB is true when|m m2(0)|<1and |m m2(γ)|<1,as shown in Fig.2(e1).3)Other Modes Below Resonant Frequency:Two other modes below the resonant frequency are discontinuous con-duction mode below resonance“2”(DCMB2)and continuous conduction mode below resonance(CCMB).Typical operation waveforms of the two modes are shown in Fig.3(e)and(f). Although these two modes are not widely designed in the LLC converter,their operations are still included in the solver for the sake of completeness.The blocks(d1),(f1),(g1),and(h1),in theflow chart in Fig.2,states the procedures to solve DCMB2 and CCMB.D.Operation Above Resonant Frequency1)Continuous Conduction Mode Above Resonance (CCMA):If the F>1,the LLC is assumed to operate in con-tinuous conduction mode above resonance(CCMA),as shown in Fig.2(a2).CCMA is a popular mode in LLC converter oper-ation.In this mode,the LLC converter voltage conversion ratio is less than unity(M<1).Typical waveforms in CCMA mode are shown in Fig.3(a).The equivalent circuit in CCMA mode inθ∈[0,α)is the circuit(b)of Fig.4.The state equations are given byθ∈[0,α)⎧⎪⎪⎪⎪⎪⎨⎪⎪⎪⎪⎪⎩m c(θ)=[m c(0)−1M−1]cos(θ)+j Lr(0)sin(θ)+1M+1(22a) m m(θ)=−1(22b) j Lr(θ)=[−m c(0)+1M+1]sin(θ)+j Lr(0)cos(θ)(22c) j Lm(θ)=j Lm(0)−λθ.(22d)The equivalent circuit inθ∈[α,γ)is the circuit(a)in Fig.4. The state equations are presented as follows:θ∈[α,γ)⎧⎪⎪⎪⎪⎪⎨⎪⎪⎪⎪⎪⎩m c(θ)=[m c(α)−1M+1]cos(θ−α)+j Lr(α)sin(θ−α)+1M−1(23a) m m(θ)=1(23b)j Lr(θ)=[−m c(α)+1M−1]sin(θ−α)+j Lr(α)cos(θ−α)(23c) j Lm(θ)=j Lm(α)+λθ.(23d) The normalized average output current is given byj out=1γγ|j Lr(θ)−j Lm(θ)|dθ=1γα[j Lm(θ)−j Lr(θ)]dθ+1γγα[j Lr(θ)−j Lm(θ)]dθ=1γαj Lm(0)−12λα2−−m c(0)+1M+1×(1−cosα)−j Lr(0)sinα+−m c(α)+1M−1×[1−cos(γ−α)]+j Lr(α)sin(γ−α)−j Lm(α)(γ−α)−12λ(γ−α)2.(24)Four equations are formulated to solve CCMA given by⎧⎪⎨⎪⎩m c(0)+m c(γ)=0(25a)j Lr(0)+j Lr(γ)=0(25b)j Lr(α)−j Lm(α)=0(25c)j out r L−1=0.(25d) Similar validation procedures are carried out.The m m2(0), m m2(α)and m m2(γ)can be calculated by(20).If|m m2(0)|≥1and|m m2(γ)|≥1,and|m m2(α)|≥1,the assumption of CCMA is true,as shown inflow chart Fig.2(b2). Otherwise the assumption of CCMA is false[Fig.2(c2)]. The assumption of operating mode changes to discontinuous conduction modes above resonance(DCMA)in this case,as shown in Fig.2(d2).2)Other Modes above Resonance:DCMA and DCMAB are two modes operating above resonant frequency.Typical opera-tion waveforms are shown in Fig.3(c)and(d).The blocks(d2), (f2),and(g2),in theflow chart in Fig.2,state the procedures to solve DCMA and DCMAB equations.Table I is presented to summarize the LLC converter operation modes,angles,and their equivalent circuits.Table II reveals the key characteristics used for validating the operation modes.III.L OSS M ODELSThe current waveforms of LLC converter are determined by the operation mode and calculated by the proposed mode solver. Current harmonics are calculated to predict losses.A numerical method is used to sample a switching cycle with n sample points. The current harmonics are calculated by fast Fourier transform, as shown in Fig.5.3250IEEE TRANSACTIONS ON POWER ELECTRONICS,VOL.27,NO.7,JULY 2012TABLE IO PERATION M ODES OF LLC CONVERTERTABLE IIV ALIDATIONS OF LLC O PERATION MODESFig.5.Transformer current waveform and harmoniccomponents.Fig.6.PSPICE-simulated primary MOSFET turn-off loss.A.Primary MOSFETThe most promising feature of the LLC converter is zero voltage switching turn-on and small turn-off current for primary side MOSFETs.A simple and effective MOSFET switching loss model is proposed for the prediction of turn-off switching loss at different turn-off currents,as shown in Fig.6(a).This proposed model utilizes a curve-fitting method to record SPICE simulation results of turn-off switching loss E off(I off).The input voltage is fixed at 330,365,and 400V in SPICE simulation,as shown in Fig.6(a).E offis nearly linearly increasing with V in from 330to 400V at a certain turn-off current level,as shown in Fig.6(b).The parameter k offis defined as the ratio of E offincreasing value from 330to 400V divided by the voltage increasing value 70V .The actual energy dissipated during switching is E off(I off,V in )E off(I off)=ae bI o f f +c (26)k off(I off)=E off(I off,400V)−E off(I off,330V)400V −330V(27)E off(I off,V in )=E off(I off,330V)+k off(I off)(V in −330).(28)It should be noted that during turn-off,there are two currents flowing through the MOSFET and the total energy value isYU et al.:COMPUTER-AIDED DESIGN AND OPTIMIZATION OF HIGH-EFFICIENCY LLC SERIES RESONANT CONVERTER 3251E off(I off,V in ).One current is to charge the output capacitance of MOSFET to V in with the energy E off(0,V in ),the other current produces energy dissipation (cannot be recovered)in the MOS-FET channel with the energy E off(I off,V in )−E off(0,V in ).During the dead-time,the energy stored in the output capac-itance of MOSFET E off(0,V in )is recovered to the input capac-itor (the drain source voltage of MOSFET drops from V in to 0,soft switching achieved).The switching loss and conduction loss of the high side and the low side primary MOSFETs (assuming the same type of MOSFETs at the high side and the low side)are denoted as P sw pri (I off,V in )and P cd pri ,respectively.The gate driving loss of primary MOSFETs is denoted as P g priP swpri (I off,V in )=2f s [E off(I off,V in )−E off(0,V in )](29)P cd pri =I 2RMSpri R ds pri(30)P gpri=Q g pri V g pri f s .(31)B.Isolation TransformerTransformer design of LLC converter is an important task toward achieving high efficiency.Here,sandwich winding is implemented in order to reduce the AC resistance of the trans-former.A center tap configuration is applied at secondary with copper foils for high current low voltage applications.Magne-tizing inductance is integrated in the isolation transformer with a certain air gap.A typical transformer structure is shown in Fig.7.The primary and secondary DC resistance R X F pri and R X F sec can be directly calculated by the winding geometry.The skin depth of the nth harmonics frequency is given byδ(n )=2ρcu2πnf s μ0.(32)The AC-to-DC resistance ratio F R at n th harmonic frequency is calculated by Dowell’s equation [20],[21],given byF R (n,p,X )=X e 2X −e −2X +2sin(2X )e 2X+e −2X −2cos(2X )+2Xp 2−13e X −e −X −2sin(X )e X +e −X +2cos(X ).(33)We have:F R pri (n )=F R (n,p,X )is for primary round con-ductors with p =n layer ,X =√πd AW G2δ(n )[21].F R sec (n )=F R (n,p,X )is for secondary foils with p =n s2and X =h f o i lδ(n ).The AC copper loss at each harmonic frequency is calculated by summing the losses from DC to 32nd harmonics.The primary side and secondary copper losses of the transformer are given byP cuX F pri=R X Fpri32 n =0F Rpri (n )I 2n pri(34)Fig.7.Winding structure of transformer.P cuX F sec=R X Fsec32 n =0F Rsec (n )I 2n sec(35)where I n pri and I n sec denote the n th order harmonic current at the primary side and the secondary side of the transformer.Flux swing of the half-bridge LLC converter is bidirectional.The peak-to-peak flux density is given byB mX F=t s 2|v Lm (t )|dtn p A e X F.(36)The empirical Steinmetz equation [19]is applied to calculate the core loss of the transformer,given byP coreX F=V eX Fkf αc o r es ΔB βc o r e m X F(37)where ΔB m X F =12B m X F is the flux swing,and k ,αcore ,and βcore are the Steinmetz coefficients provided by the manu-facturer [22].C.Resonant InductorA separate resonant inductor is applied in the LLC converter.The separate inductor is used because it simplifies the resonance design process.Integrated transformer may lead to totally dif-ferent loss models,designs,and optimization procedures.The losses in the resonant inductor are copper loss and core loss.The DC resistance of resonant inductor is calculated ac-cording to its geometry.Dowell’s equation (33)is also applied to calculate AC resistance.F R Lr (n )=F R (n,p,X )is for reso-nant inductor,with p =n Lr layer ,X =√πd L r AW G2δ(n ).The copper loss of resonant inductor is given byP cuLr=R Lr32 n =0F RLr (n )I 2n pri .(38)Core loss of resonant inductor is given byP coreLr=V eLr kf αc o r es ΔB βc o r e m Lr(39)where ΔB m Lr=L r I L r m a x n L r A e L ris the flux swing of resonantinductor.。