Resonant Hybrid Flyback, a New Topology for High Density Power Adaptors

In this article, an innovative power adaptor based on the asymmetrical pulse width modulation (PWM) flyback topology will be presented. Its benefits compared to other state-of-the-art topologies, such as the active clamp flyback, are analyzed in detail. It will also describe the control methods to achieve high efficiency and power density using zero-voltage switching (ZVS) and zero-current switching (ZCS) techniques over the full range of the input voltage and the output load, providing comprehensive guidelines for the practical design. Finally, we demonstrate the convenience of the proposed design methods with a 65 W adaptor prototype achieving a peak efficiency of close to 95% and a minimum efficiency of 93.4% at full load over the range of the input voltage, as well as a world-class power density of 22 W/inch3 cased.This research is financed by Infineon Tecnologias AG

Single Stage Flyback Micro-Inverter for Solar Energy Systems

ABSTRACT Solar energy systems based on photovoltaic (PV) cells have attracted considerable interest in recent years due to their promise of clear and seemingly limitless generated energy. Solar energy systems based on micro-inverter architectures are gaining in popularity as they are less prone to shading and PV cell malfunction since each solar panel in a system has its own low power inverter. A number of micro-inverters are single stage flyback inverters that are based on the DC-DC flyback topologies. There have been numerous papers on the topic of how to improve the efficiency of dc-dc flyback converters but as far as improving the efficiency of dc-ac flyback micro-inverter is concerned, comparatively less investigation on efficiency improvement has been performed. A low cost technique for improving the efficiency of a basic dc-ac flyback micro-inverter is proposed in the paper. The proposed efficiency improving technique is based on a simple snubber, consisting of just a few passive elements. In the thesis, the flyback micro-inverter with the passive snubber is presented; the modes of operation of the converter are discussed as well as the design of the converter with the passive snubber. Experimental results obtained from a lab prototype are presented as well. A second novel technique for improving the efficiency of a single stage flyback micro-inverter is also proposed. The technique is based on combining the simple passive snubber with a variable frequency control zero-voltage switching (ZVS) technique. In the thesis, the operation of the micro-inverter with both the passive snubber and the ZVS technique is explained and the design of the converter is discussed. Experimental results obtained from a lab prototype are presented to confirm the effectiveness of the both the techniques

Highly Integrated Dc-dc Converters

A monolithically integrated smart rectifier has been presented first in this work. The smart rectifier, which integrates a power MOSFET, gate driver and control circuitry, operates in a self-synchronized fashion based on its drain-source voltage, and does not need external control input. The analysis, simulation, and design considerations are described in detail. A 5V, 5-µm CMOS process was used to fabricate the prototype. Experimental results show that the proposed rectifier functions as expected in the design. Since no dead-time control needs to be used to switch the sync-FET and ctrl-FET, it is expected that the body diode losses can be reduced substantially, compared to the conventional synchronous rectifier. The proposed self-synchronized rectifier (SSR) can be operated at high frequencies and maintains high efficiency over a wide load range. As an example of the smart rectifier\u27s application in isolated DC-DC converter, a synchronous flyback converter with SSR is analyzed, designed and tested. Experimental results show that the operating frequency could be as high as 4MHz and the efficiency could be improved by more than 10% compared to that when a hyper fast diode rectifier is used. Based on a new current-source gate driver scheme, an integrated gate driver for buck converter is also developed in this work by using a 0.35µm CMOS process with optional high voltage (50V) power MOSFET. The integrated gate driver consists both the current-source driver for high-side power MOSFET and low-power driver for low-side power iv MOSFET. Compared with the conventional gate driver circuit, the current-source gate driver can recovery some gate charging energy and reduce switching loss. So the current-source driver (CSD) can be used to improve the efficiency performance in high frequency power converters. This work also presents a new implementation of a power supply in package (PSiP) 5MHz buck converter, which is different from all the prior-of-art PSiP solutions by using a high-Q bondwire inductor. The high-Q bondwire inductor can be manufactured by applying ferrite epoxy to the common bondwire during standard IC packaging process, so the new implementation of PSiP is expected to be a cost-effective way of power supply integration

Investigation of Dual-Stage High Efficiency and Density Micro Inverter for Solar Application

Module integrated converters (MIC), also called micro inverter, in single phase have witnessed recent market success due to unique features (1) improved energy harvest, (2) improved system efficiency, (3) lower installation costs, (4) plug-N-play operation, (5) and enhanced flexibility and modularity. The MIC sector has grown from a niche market to mainstream, especially in the United States. Due to the fact that two-stage architecture is commonly used for single phase MIC application. A DC-DC stage with maximum power point tracking to boost the output voltage of the Photovoltaic (PV) panel is employed in the first stage, DC-AC stage is used for use to connect the grid or the residential application. As well known, the cost of MIC is key issue compared to convention PV system, such as the architecture: string inverter or central inverter. A high efficiency and density DC-DC converter is proposed and dedicated for MIC application. Assuming further expansion of the MIC market, this dissertation presents the micro-inverter concept incorporated in large size PV installations such as MW-class solar farms where a three phase AC connection is employed. A high efficiency three phase MIC with two-stage ZVS operation for grid tied photovoltaic system is proposed which will reduce cost per watt, improve reliability, and increase scalability of MW-class solar farms through the development of new solar farm system architectures. This dissertation presents modeling and triple-loop control for a high efficiency three-phase four-wire inverter for use in grid-connected two-stage micro inverter applications. An average signal model based on a synchronous rotation frame for a three-phase four-wire inverter has been developed. The inner current loop consists of a variable frequency bidirectional current mode (VFBCM) controller which regulates output filter inductor current thereby achieving ZVS, improved system response, and reduced grid current THD. Active damping of the LCL output filter using filter inductor current feedback is discussed along with small signal modeling of the proposed control method. Since the DC-link capacitor plays a critical role in two-stage micro inverter applications, a DC-link controller is implemented outside of the two current control loops to keep the bus voltage constant. In the end, simulation and experimental results from a 400 watt prototype are presented to verify the validity of the theoretical analysis