High power density AC to DC conversion with reduced input current harmonics

PhD ThesisThis thesis investigates the bene ts and challenges arising from the use of minimal capacitance in AC to DC converters. The purpose of the research is to ultimately improve the power density and power factor of electrical systems connected to the grid. This is carried out in the con- text of a low cost brushless DC drive system operating from an o ine power supply. The work begins with a review of existing applications where it is prac- tical to use a limited amount of DC link capacitance. The vast majority of these have a load which is insensitive to supply power variations at twice the line frequency. Low performance motor drives are found to be the most prevalent, with the inertia of the rotor mitigating the e ect of torque ripple. Further research is carried out on active power factor cor- rection techniques suitable for this application, leading to the conclusion that no appropriate systems exist. A power supply is developed to enable a 24V, 200W brushless motor drive to operate from the mains. The system runs successfully using only 1µF of DC link capacitance, which causes the motor supply volt- age to have 100% ripple. It is noted that whilst this drastically reduces the low frequency input current harmonics, those occurring at the load switching frequency are greatly increased. To combat this, a novel active power factor correction system is proposed using a notch lter to detect the input current error. The common problem of voltage feedback ripple is avoided by eliminating the voltage control loop altogether. The main limitations are identi ed as a high sensitivity to load step changes and variations in line frequency. Despite this, a high power factor is maintained in all operating conditions, as well as compliance with the relevant harmonic standards.Dyson Technology Ltd and Newcastle Univer- sit

GaN-Based High Efficiency Transmitter for Multiple-Receiver Wireless Power Transfer

Wireless power transfer (WPT) has attracted great attention from industry and academia due to high charging flexibility. However, the efficiency of WPT is lower and the cost is higher than the wired power transfer approaches. Efforts including converter optimization, power delivery architecture improvement, and coils have been made to increase system efficiency.In this thesis, new power delivery architectures in the WPT of consumer electronics have been proposed to improve the overall system efficiency and increase the power density.First, a two-stage transmitter architecture is designed for a 100 W WPT system. After comparing with other topologies, the front-end ac-dc power factor correction (PFC) rectifier employs a totem-pole rectifier. A full bridge 6.78 MHz resonant inverter is designed for the subsequent stage. An impedance matching network provides constant transmitter coil current. The experimental results verify the high efficiency, high PF, and low total harmonic distortion (THD).Then, a single-stage transmitter is derived based on the verified two-stage structure. By integration of the PFC rectifier and full bridge inverter, two GaN FETs are saved and high efficiency is maintained. The integrated DCM operated PFC rectifier provides high PF and low THD. By adopting a control scheme, the transmitter coil current and power are regulated. A simple auxiliary circuit is employed to improve the light load efficiency. The experimental results verify the achievement of high efficiency.A closed-loop control scheme is implemented in the single-stage transmitter to supply multiple receivers simultaneously. With a controlled constant transmitter current, the system provides a smooth transition during dynamically load change. ZVS detection circuit is proposed to protect the transmitter from continuous hard switching operation. The control scheme is verified in the experiments.The multiple-reciever WPT system with the single-stage transmitter is investigated. The system operating range is discussed. The method of tracking optimum system efficiency is studied. The system control scheme and control procedure, targeting at providing a wide system operating range, robust operation and capability of tracking the optimized system efficiency, are proposed. Experiment results demonstrate the WPT system operation

A New Single-Phase Single-Stage AC-DC Stacked Flyback Converter With Active Clamp ZVS

Single-stage AC-DC converters integrate an AC-DC front-end converter with a DC-DC back-end converter. Compared with conventional two-stage AC-DC converters, single-stage AC-DC converters use less components and only one controller, which is used to regulate the output voltage. As a result, the cost, size and complexity of AC-DC converters can be reduced, but single-stage converters do not perform as well as two-stage converters, and most have drawbacks that are related to the fact that the DC bus voltage is not controlled an can become excessive. A new single-phase single-stage AC-DC converter that uses stacked flyback converters is proposed in this thesis. The proposed converter consists of two low power flyback converters stacked on top of each other and an active clamp that helps the main switches operate with ZVS. The stacked structure helps reduce the voltage stresses typical fund in many single-stage converters. In the thesis, the operation of the converter is explained, the steady-state characteristics of the converter are determined and its design is discussed. The feasibility of the new converter is confirmed with experimental results obtained from a 100VAC~220VAC worldwide input, 48V output, 100kHz switching frequency and 200 W output power prototype converter

Long Life Single Stage PFC/SLC Converter driving LEDs

Licht emittierende Dioden (LEDs) sind heutzutage für Beleuchtungsanwendungen Stand der Technik und daher allgegenwärtig. Langlebige Beleuchtungsanwendungen erfordern allerdings ein robustes Systemdesign. Daher wurde die typische Ausfallursache von LED-Leuchten ermittelt: Die Stromversorgung ist mit 52% die wahrscheinlichste Ausfallursache. In manchen Anwendungen muss der LED Treiber theoretisch zehn Mal ausgetauscht werden, bevor die Lebensdauergrenze des LED-Moduls erreicht wird. Diese Arbeit beschäftigt sich daher mit der Entwicklung eines langlebigen, einstufigen LED Treibers, welcher aus einer Leistungsfaktorkorrektur (PFC) und einem Serien LC (SLC) Wandler besteht. Ein Großteil der Ausfälle des LED-Treibers wird dabei durch den Elektrolytkondensator verursacht. Durch den Ersatz des Elektrolytkondensators durch einen Filmkondensator wird prognostiziert, dass die Lebensdauer der Leuchte deutlich erhöht werden kann. Im Abschnitt 4 werden verschiedene LED-Treibertechnologien und Topologien analysiert. Nach einer ganzheitlichen Topologieanalyse wurde die PFC/SLC-Topologie gewählt. Die dabei verwendete diskontinuierliche totem pole Leistungsfaktorkorrektur (PFC) und der Serien LC Wandler wurden im Zeitbereich analysiert. Für beide Wandler wird der durchschnittliche Eingangsstrom bzw. der durchschnittliche Ausgangsstrom bestimmt. Da zwei Stellgrößen gleichzeitig eingestellt werden müssen, der AC-Eingangsstrom und der DC-Ausgangsstrom, sind für die Steuerung zwei Freiheitsgrade erforderlich. Die PFC- und SLC-Übertragungsfunktionen werden jeweils durch Frequenz und Tastgrad gesteuert. Dazu wurde eine Lösungsfunktion entwickelt, welche die Frequenz und den Tastgrad in Abhängigkeit von Eingangsleitwert, Ausgangsstrom und mehreren Messwerten berechnet. Durch die Erfassung der Zwischenkreisspannung und der Ausgangsspannung wirken sich deren Änderungen nur minimal auf den Ausgangsstrom aus. Dies erlaubt einen höheren Spannungsripple am Zwischenkreiskondensator, und damit den Ersatz von Elektrolytkondensatoren durch Folienkondensatoren. Die Lebensdauer des LED-Treibers wird dadurch deutlich steigert. Für den verwendeten Regelalgorithmus müssen mehrere Spannungen und Ströme gleichzeitig gemessen und digital gefiltert werden. Beispielsweise wird die Zwischenkreisspannung zuerst analog gefiltert, dann AD gewandelt und erneut digital durch einen resonanten Beobachter gefiltert. So kann die doppelte Netzfrequenz im Zwischenkreiskondensator herausgefiltert werden. Weiterhin wird ein Verfahren zur galvanisch getrennten Spannungsmessung entwickelt. Dadurch kann die Steuerung auf der Primärseite platziert werden, während die Sekundärseite genau gemessen werden kann. Auf Grundlage der vorgeschlagenen Messschaltung werden Schutzkonzepte entwickelt, um eine Selbstzerstörung oder Schädigung während des Betriebs vorzubeugen. Um die Anzahl der LEDs in einem LED-Modules zu erhöhen, z. B. um kleinere MidPower-LEDs anstelle von HighPower-LEDs einzusetzen, wird eine neuartige Parallelschaltungskonzept für LEDs entwickelt. Die Schaltung misst die einzelnen Strangströme, bildet dann einen Mittelwert aus den einzelnen Strangströmen, welcher wiederum dann als Vorgabewert genutzt wird. Auf diese Weise können LEDs sicher, und ohne Beeinträchtigung der Effizienz und Lebensdauer parallel geschaltet werden. Für den Betrieb des LED-Treibers wird ein ausgeklügeltes Hilfsspannungskonzept zur Selbstversorgung entwickelt. Da die Regelung digital implementiert ist, ist ein tiefgreifendes Softwareengineering erforderlich, um die Echtzeitperformance der CPU sicherzustellen. Eine unzureichende Implementierung der Regelungssoftware führt zu einem instabilen Regelkreis. Die Messungen am Ende der Arbeit zeigen, dass ein langlebiger, flimmerfreier LED-Treiber entwickelt wurde. Der Netzeingangsstrom ist dabei sinusförmig, während der LED Ausgangsstrom nahezu konstant ist. Der maximale Wirkungsgrad des LED-Treibers wurde zu 93% bestimmt

Double Resonant High-Frequency Converters for Wireless Power Transfer

This thesis describes novel techniques and developments in the design and implementation of a low power radio frequency (40kHz to 1MHz) wireless power transfer (WPT) system, with an application in the wireless charging of autonomous drones without physical connection to its on-board Battery Management System (BMS). The WPT system is developed around a matrix converter exploiting the benefits such as a small footprint (DC-link free), high efficiency and high power density. The overall WPT system topology discussed in this thesis is based on the current state-of-the-art found in literature, but enhancements are made through novel methods to further improve the converter’s stability, reduce control complexity and improve the wireless power efficiency. In this work, each part of the system is analysed and novel techniques are proposed to achieve improvements. The WPT system design methodology presented in this thesis commences with the use of a conventional full-bridge converter. For cost-efficiency and to improve the converters stability, a novel gate drive circuit is presented which provides self-generated negative bias such that a bipolar MOSFET drive can be driven without an additional voltage source or magnetic component. The switching control sequences for both a full-bridge and single phase to single phase matrix converter are analysed which show that the switching of a matrix converter can be considered to be the same as a full-bridge converter under certain conditions. A middleware is then presented that reduces the complexity of the control required for a matrix converter and enables control by a conventional full-bridge controller (i.e. linear controller or microcontroller). A novel technique that can maximise and maintain in real-time the WPT efficiency is presented using a maximum efficiency point tracking approach. A detailed study of potential issues that may affect the implementation of this novel approach are presented and new solutions are proposed. A novel wireless pseudo-synchronous sampling method is presented and implemented on a prototype system to realise the maximum efficiency point tracking approach. Finally, a new hybrid wireless phase-locked loop is presented and implemented to minimise the bandwidth requirements of the maximum efficiency point tracking approach. The performance and methods for implementation of the novel concepts introduced in this thesis are demonstrated through a number of prototypes that were built. These include a matrix converter and two full WPT systems with operating frequencies ranging from sub-megahertz to megahertz level. Moreover, the final prototype is applied to the charging of a quadcopter battery pack to successfully charge the pack wirelessly whilst actively balancing the cells. Hence, fast battery charging and cell balancing, which conventionally requires battery removal, can be achieved without re-balance the weight of the UAV

Dynamic modeling of pwm and single-switch single-stage power factor correction converters

The concept of averaging has been used extensively in the modeling of power electronic circuits to overcome their inherent time-variant nature. Among various methods, the PWM switch modeling approach is most widely accepted in the study of closed-loop stability and transient response because of its accuracy and simplicity. However, a non-ideal PWM switch model considering conduction losses is not available except for converters operating in continuous conduction mode (CCM) and under small ripple conditions. Modeling of conductor losses under large ripple conditions has not been reported in the open literature, especially when the converter operates in discontinuous conduction mode (DCM). In this dissertation, new models are developed to include conduction losses in the non-ideal PWM switch model under CCM and DCM conditions. The developed model is verified through two converter examples and the effect of conduction losses on the steady state and dynamic responses of the converter is also studied. Another major constraint of the PWM switch modeling approach is that it heavily relies on finding the three-terminal PWM switch. This requirement severely limits its application in modeling single-switch single-stage power factor correction (PFC) converters, where more complex topological structures and switching actions are often encountered. In this work, we developed a new modeling approach which extends the PWM switch concept by identifying the charging and discharging voltages applied to the inductors. The new method can be easily applied to derive large-signal models for a large group of PFC converters and the procedure is elaborated through a specific example. Finally, analytical results regarding harmonic contents and power factors of various PWM converters in PFC applications are also presented here

Battery charging system incorporating an equalisation circuit for electric vehicles

Ph.D. ThesisHybrid electric vehicles (HEVs) and electric vehicles (EVs) are gaining in popularity mainly due to the fact that unlike combustion-powered vehicles, they do not pollute with greenhouse gases and toxic particles. Most HEVs and EVs are powered by lithium-ion battery packs which have high power density and longer cycle lives compared to other battery types. Each pack is made out of many battery cells in series connected and due to manufacturing tolerances and chemical processes in individual cells each cell has its own electric characteristics. In order to achieve a balanced voltage across all cells, a battery management system (BMS) must be employed to actively monitor and balance the cells voltage. On-board battery chargers are installed in HEVs/EVs to charge the lithium-ion battery pack from the grid. This charger converts AC grid voltage into a controllable DC output voltage, but it adds weight to the vehicle, reducing the overall efficiency of an HEV/EV and also increasing its cost. The aim of researches in multi-functional power electronics is to design systems which perform several different functions at the same time. These systems promise cost and weight reductions since only one circuit is used to conduct different functions. An example is the electric drive in an HEV/EV. On one hand, it propels the car forward when driving, while on the other hand the battery can be charged via a modified electric motor and inverter topology. Thus, no additional on-board charger is required. This thesis describes a new multi-functional circuit for HEVs/EVs which combines the functions of voltage equalisation with grid charging. Compared to a drive system, the proposed circuit does not rely on an electric motor to charge the battery. Various battery chargers and equalisation circuits are first compared. Then, the design of the proposed circuit is described and simulation results are presented for charging and voltage balancing. An experimental test rig was built and practical results have been captured and compared with simulation results for validation. The advantages and disadvantages of the proposed circuit are discussed at the end of the thesis. Keywords- Multi-functional system, Battery charging, Voltage equalisation, Lithium-ion batter

High-Voltage Stations for Electric Vehicle Fast-Charging: Trends, Standards, Charging Modes and Comparison of Unity Power-Factor Rectifiers

Emission of greenhouse gases and scarcity of fossil fuels have put the focus of the scientific community, industry and society on the electric vehicle (EV). In order to reduce CO2 emissions, cutting-edge policies and regulations are being imposed worldwide, where the use of EVs is being encouraged. In the best of scenarios reaching 245 million EVs by 2030 is expected. Extensive use of EV-s requires the installation of a wide grid of charging stations and it is very important to stablish the best charging power topology in terms of efficiency and impact in the grid. This paper presents a review of the most relevant issues in EV charging station power topologies. This review includes the impact of the battery technology, currently existing standards and proposals for power converters in the charging stations. In this review process, some disadvantages of current chargers have been identified, such as poor efficiency and power factor. To solve these limitations, five unidirectional three-phase rectifier topologies have been proposed for fast EV charging stations that enhance the current situation of chargers. Simulation results show that all the proposed topologies improve the power factor issue without penalizing efficiency. The topologies with the best overall performance are the Vienna 6-switch and the Vienna T-type rectifier. These two converters achieve high efficiency and power factor, and they allow a better distribution of losses among semiconductors, which significantly increase the life-cycle of the semiconductor devices and the reliability of the converter.This work was supported in part by the Government of the Basque Country through the Fund for Research Groups of the Basque University System under Grant IT978-16, in part by the Research Program ELKARTEK under Project ENSOL2-KK-2020/00077 and Project HARVESTGEN-KK-2020/00113, in part by the Ministerio de Ciencia e Innovacion of Spain under Project PID2020-115126RB-I00, and in part by the FEDER Funds. Documen

Advances in Control of Power Electronic Converters

This book proposes a list of contributions in the field of control of power electronics converters for different topologies: DC-DC, DC-AC and AC-DC. It particularly focuses on the use of different advanced control techniques with the aim of improving the performances, flexibility and efficiency in the context of several operation conditions. Sliding mode control, fuzzy logic based control, dead time compensation and optimal linear control are among the techniques developed in the special issue. Simulation and experimental results are provided by the authors to validate the proposed control strategies