Advanced Control Techniques for Efficiency and Power Density Improvement of a Three-Phase Microinverter

Inverters are widely used in photovoltaic (PV) based power generation systems. Most of these systems have been based on medium to high power string inverters. Microinverters are gaining popularity over their string inverter counterparts in PV based power generation systems due to maximized energy harvesting, high system reliability, modularity, and simple installation. They can be deployed on commercial buildings, residential rooftops, electric poles, etc and have a huge potential market. Emerging trend in power electronics is to increase power density and efficiency while reducing cost. A powerful tool to achieve these objectives is the development of an advanced control system for power electronics. In low power applications such as solar microinverters, increasing the switching frequency can reduce the size of passive components resulting in higher power density. However, switching losses and electromagnetic interference (EMI) may increase as a consequence of higher switching frequency. Soft switching techniques have been proposed to overcome these issues. This dissertation presents several innovative control techniques which are used to increase efficiency and power density while reducing cost. Dynamic dead time optimization and dual zone modulation techniques have been proposed in this dissertation to significantly improve the microinverter efficiency. In dynamic dead time optimization technique, pulse width modulation (PWM) dead times are dynamically adjusted as a function of load current to minimize MOSFET body diode conduction time which reduces power dissipation. This control method also improves total harmonic distortion (THD) of the inverter output current. To further improve the microinverter efficiency, a dual-zone modulation has been proposed which introduces one more soft-switching transition and lower inductor peak current compared to the other boundary conduction mode (BCM) modulation methods. In addition, an advanced DC link voltage control has been proposed to increase the microinverter power density. This concept minimizes the storage capacitance by allowing greater voltage ripple on the DC link. Therefore, the microinverter reliability can be significantly increased by replacing electrolytic capacitors with film capacitors. These control techniques can be readily implemented on any inverter, motor controller, or switching power amplifier. Since there is no circuit modification involved in implementation of these control techniques and can be easily added to existing controller firmware, it will be very attractive to any potential licensees

Modulation and Control Techniques for Performance Improvement of Micro Grid Tie Inverters

The concept of microgrids is a new building block of smart grid that acts as a single controllable entity which allows reliable interconnection of distributed energy resources and loads and provides alternative way of their integration into power system. Due to its specifics, microgrids require different control strategies and dynamics of regulation as compared to ones used in conventional utility grids. All types of power converters used in microgrid share commonalities which potentially affect high frequency modes of microgrid in same manner. There are numerous unique design requirements imposed on microgrid tie inverters, which are dictated by the nature of the microgrid system and bring major challenges that are reviewed and further analyzed in this work. This work introduces, performs a detailed study on, and implements nonconventional control and modulation techniques leading to performance improvement of microgrid tie inverters in respect to aforementioned challenges

High Power Density, High Efficiency Single Phase Transformer-less Photovoltaic String Inverters

abstract: Two major challenges in the transformer-less, single-phase PV string inverters are common mode leakage currents and double-line-frequency power decoupling. In the proposed doubly-grounded inverter topology with innovative active-power-decoupling approach, both of these issues are simultaneously addressed. The topology allows the PV negative terminal to be directly connected to the neutral, thereby eliminating the common-mode ground-currents. The decoupling capacitance requirement is minimized by a dynamically-variable dc-link with large voltage swing, allowing an all-film-capacitor implementation. Furthermore, the use of wide-bandgap devices enables the converter operation at higher switching frequency, resulting in smaller magnetic components. The operating principles, design and optimization, and control methods are explained in detail, and compared with other transformer-less, active-decoupling topologies. A 3 kVA, 100 kHz single-phase hardware prototype at 400 V dc nominal input and 240 V ac output has been developed using SiC MOSFETs with only 45 μF/1100 V dc-link capacitance. The proposed doubly-grounded topology is then extended for split-phase PV inverter application which results in significant reduction in both the peak and RMS values of the boost stage inductor current and allows for easy design of zero voltage transition. A topological enhancement involving T-type dc-ac stage is also developed which takes advantage of the three-level switching states with reduced voltage stress on the main switches, lower switching loss and almost halved inductor current ripple. In addition, this thesis also proposed two new schemes to improve the efficiency of conventional H-bridge inverter topology. The first scheme is to add an auxiliary zero-voltage-transition (ZVT) circuit to realize zero-voltage-switching (ZVS) for all the main switches and inherent zero-current-switching (ZCS) for the auxiliary switches. The advantages include the provision to implement zero state modulation schemes to decrease the inductor current THD, naturally adaptive auxiliary inductor current and elimination of need for large balancing capacitors. The second proposed scheme improves the system efficiency while still meeting a given THD requirement by implementing variable instantaneous switching frequency within a line frequency cycle. This scheme aims at minimizing the combined switching loss and inductor core loss by including different characteristics of the losses relative to the instantaneous switching frequency in the optimization process.Dissertation/ThesisDoctoral Dissertation Electrical Engineering 201

Two-stage optimization method for efficient power converter design including light load operation

Power converter efficiency is always a hot topic for switch mode power supplies. Nowadays, high efficiency is required over a wide load range, e.g., 20%, 50% and 100% load. Computer-aided design optimization is developed in this research work, to optimize off-line power converter efficiency from light load to full load. A two-stage optimization method to optimize power converter efficiency from light load to full load is proposed. The optimization procedure first breaks the converter design variables into many switching frequency loops. In each fixed switching frequency loop, the optimal designs for 20%, 50% and 100% load are derived separately in the first stage, and an objective function using the optimization results in the first stage is formed in the second stage to consider optimizing efficiency at 20%, 50% and 100% load. Component efficiency models are also established to serve as the objective functions of optimizations. Prototypes 400V to 12V/25A 300W two-FET forward converters are built to verify the optimization results

Three-Level Converters for Low Voltage Active Front End Motor Drives

Electric drives with Active Front End (AFE) converters can provide benefits such as lower harmonic current injections to the grid, smaller size filters, lower THD values and cost saving for injection of power to the grid in brake situations. SiC-MOSFET based two-level converters can be a promising topology for Active Front End (AFE) application in electric drives. The possibility of high switching frequency will make the grid filters smaller. Grid filters are used for EMC and power quality issues. However, there are practical limitations for increasing the switching frequency such as dead time in the gating signals, sampling requirements, and electro-magnetic interference (EMI) considerations, besides the need for high frequency magnetic material for the LCL line filter. However, three-level converters provide the opportunity to switch at a lower frequency and also reduce the filter size compared to a two-level IGBT converter. Three-level converters can be built using low voltage rated modules with lower switching losses and reduced cost compared to SiC based two-level converters. In this work, a comparison between three-level converters and two-level converters is presented focusing on power loss, filter size and application benefits. This comparison is based on an optimization algorithm with the objective function of weight, volume and cost. The topologies and modulation techniques for multilevel converter are categorized at first by a thorough literature survey. The pros and cons for various multilevel topologies and modulation techniques are discussed. The 3-level neutral point clamped (NPC) topology is selected to build a 25 hp, 480V power conversion system. LCL filter design for comparability with grid requirements has been done and the optimal size of the LCL filter is derived considering thermal limitations.\par To make the comparison between different topologies and switch types possible, it is necessary to consider the maximum junction temperature relation to the switching frequency. In this work, a new modulation method is proposed to improve the performance of three-level converters considering losses and thermal performance. Also, a thermal model is derived for SiC MOSFET power modules that takes the effect of MOSFET channel conduction into consideration. Losses for different modulation methods is analysed and compared for two-level and three-level converters. For a specific application of drives, low speed operation is investigated and the comparison between three-level and two-level converters is considered. The methods for calculating losses are considered carefully to ensure maximizing the utilization of the power semiconductors (for highest power density designs). A novel modulation method is developed for low speed operation of power converters. Finally, an optimization is done for finding minimum volume, highest efficiency, minimum common mode pulses and complying with EMI constraints. This optimization has been broken into multiple steps for reducing the problem size. This will enable us to validate the results more efficiently. Some parts of this optimization are done automatically such as the inductor magnetic and thermal design

Digital Control of Power Converters and Drives for Hybrid Traction and Wireless Charging

In the last years environmental issues and constant increase of fuel and energy cost have been incentivizing the development of low emission and high efficiency systems, either in traction field or in distributed generation systems from renewable energy sources. In the automotive industry, alternative solutions to the standard internal combustion engine (ICE) adopted in the conventional vehicles have been developed, i.e. fuel cell electric vehicles (FCEVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEV) or pure electric vehicles (EVs), also referred as battery powered electric vehicles (BEV). Both academic and industry researchers all over the world are still facing several technical development areas concerning HEV components, system topologies, power converters and control strategies. Efficiency, lifetime, stability and volume issues have moved the attention on a number of bidirectional conversion solutions, both for the energy transfer to/from the storage element and to/from the electric machine side. Moreover, along with the fast growing interest in EVs and PHEVs, wireless charging, as a new way of charging batteries, has drawn the attention of researchers, car manufacturers, and customers recently. Compared to conductive power transfer (usually plug-in), wireless power transfer (WPT) is more convenient, weather proof, and electric shock protected. However, there is still more research work needs to be done to optimize efficiency, cost, increase misalignment tolerance, and reduce size of the WPT chargers. The proposed dissertation describes the work from 2012 to 2014, during the PhD course at the Electric Drives Laboratory of the University of Udine and during my six months visiting scholarship at the University of Michigan in Dearborn. The topics studied are related to power conversion and digital control of converters and drives suitable for hybrid/electric traction, generation from renewable energy sources and wireless charging applications. From the theoretical point of view, multilevel and multiphase DC/AC and DC/DC converters are discussed here, focusing on design issues, optimization (especially from the efficiency point-of-view) and advantages. Some novel modulation algorithms for the neutral-point clamped three-level inverter are presented here as well as a new multiphase proposal for a three-level buck converter. In addition, a new active torque damping technique in order to reduce torque oscillations in internal combustion engines is proposed here. Mainly, two practical implementations are considered in this dissertation, i.e. an original two-stage bi-directional converter for mild hybrid traction and a wireless charger for electric vehicles fast charge

Optimized design of a high input-voltage-ripple-rejection converter for LED lighting

The asymmetrical half-bridge (AHB) converter has been deeply analyzed as second stage in ac–dc light emitting diode (LED) drivers. Galvanic isolation, high reliability and high efficiency are their main advantages while a limited duty cycle range (i.e., 0–0.5) and a poor dynamic behavior are their main disadvantages. As second stage of an LED driver, the most demanding requirement for its control loop is cancelling the low-frequency ripple introduced by the first stage. According to its limited maximum attainable bandwidth, this is normally achieved by implementing a feedforward loop. Nonetheless, the static gain of the standard AHB converter presents a nonlinear relation between the output voltage and the duty cycle. As a consequence, the effectiveness of this feedforward loop is limited. In this paper, the use of the zeta AHB converter as second stage of an LED driver is analyzed and an optimized design is proposed. Regarding its advantages, it presents an extended duty cycle range (theoretically, 0–1.0). Besides, it presents a linear relation between the output voltage and the duty cycle. Therefore, although its dynamic behavior is still limited, it can perfectly cancel the low-frequency ripple introduced by the first stage of the LED driver by means of a straightforward feedforward loop. The optimized design proposed in this paper is focused on minimizing the losses in the magnetic components (transformer and inductor) by wisely choosing the value of the two turns ratios of the transforme

AC Current Ripple in Three-Phase Four-Leg PWM Converters with Neutral Line Inductor

This paper presents a comprehensive study of peak-to-peak and root-mean-square (RMS) values of AC current ripples with balanced and unbalanced fundamental currents in a generic case of three-phase four-leg converters with uncoupled AC interface inductors present in all three phases and in neutral. The AC current ripple characteristics were determined for both phase and neutral currents, considering the sinusoidal pulse-width modulation (SPWM) method. The derived expressions are simple, effective, and ready for accurate AC current ripple calculations in three- or four-leg converters. This is particularly handy in the converter design process, since there is no need for heavy numerical simulations to determine an optimal set of design parameters, such as switching frequency and line inductances, based on the grid code or load restrictions in terms of AC current ripple. Particular attention has been paid to the performance comparison between the conventional three-phase three-leg converter and its four-leg counterpart, with distinct line inductance values in the neutral wire. In addition to that, a design example was performed to demonstrate the power of the derived equations. Numerical simulations and extensive experimental tests were thoroughly verified the analytical developments