Optimized Thermal Management and Over-Current Protection in a Portable Three-Phase AC-DC Rectifier

This study presents the design, implementation, and analysis of a portable three-phase AC-DC rectifier module with optimized thermal management and overcurrent protection, targeting enhanced efficiency and reliability for academic and research applications. Objectives included developing a robust rectifier system capable of converting three-phase AC to stable DC output, implementing effective thermal management to mitigate heat buildup, and integrating a reliable overcurrent protection mechanism. Methods involved hardware design and assembly, including component selection, PCB layout, and thermal management via aluminum heat sinks and forced-air cooling. Simulation studies using MATLAB/Simulink compared single-phase and three-phase rectifier configurations. Real-time current monitoring and control were implemented using an Arduino UNO, triggering a relay for overcurrent protection. Thermal analysis was conducted using a thermal camera under varying load conditions, with and without fan cooling. Results demonstrated the successful conversion of 95.6V AC to 220V DC, with fan cooling reducing the temperature rise at 10A from 48.6°C to 36.4°C. The overcurrent protection effectively triggered at 9A, ensuring safe operation. Contributions include a comprehensive design methodology for portable rectifier modules, quantitative thermal performance analysis, and the integration of intelligent overcurrent protection, demonstrating the feasibility of efficient and reliable power conversion for research and educational purposes.