Generating DC 50V DC 1000Amps from 3 phase mains supply

[KiranVSutar]

Hi Forum Members,

I have an enquiry to develop a Microcontroller based unit that converts 3-phase mains supply into 50Volts, 1000Amps. (Max.).

The current Limit is dependant upon the model. We can have 50Amps, 100Amps, 200Amps, 500Amps or 1000Amps (max.).

As per the SetCurrent, I am supposed to change the voltage so that the SetCurrent is achieved.

I have a lot of experience in microcontroller based products, but NOT so much in Power Electronics.

Can somebody give links, Schematics, AppNotes, or help me out on this project?

Thanks.

 

[umery2k75]

First figure out the topology you want to use, there are many. Decide about the controller in the end.

 

[FvM]

The power stage schematics are more or less simple. But a lot of information is missing in a schematic, particularly assembly
technique, wiring. You may want to study how existing multi kW power supply are built. And you should calculate
possible failure of a first or second attempt. It's better to wear hearing protectors when testing your prototype circuits. Exploding
power modules or capacitors are no fun.

 

[KiranVSutar]

Many thanks FvM and umery2k75,

Guess what, I don't even know the topologies.
But I guess, This might work, based on the feedback from customer, other engineers, Internet (particularly EDABoard), etc...

Use a 3phase step down transformer with HexPhase output with Neutral (Secondary Side).
Use 3 sets of SCR-SCR between each Secondary phase. And trigger the SCRs in a sequence to produce the DC.
The SCRs will be having a current rating of 500Amps.

So my queries are:
1. Will the above method work? What should be the exact schematic for this method ? What capacitors/resistors/inductors to use for the safety of the SCRs and my circuitry?
2. Can we use the 3phase Half Bridge Method ? And Can a HexPhase transformer be used for 3phase Half Bridge? Half-Bridge, is the one with SCR-Diode in each phase.
3. I will be providing a lot of Heat Sinking, OverCurrent Safety, and HeatSink Temperature Monitoring. Do I need to take care of any other parameter ?

Assembly technique and Wiring will be taken care of by another Electrical Engineer and is out of scope of my work in this project.

Awaiting your valuable comments. Thanks.