Soft-Switched Step-Up Medium Voltage Power Converters

With a ten-year average annual growth rate of 19 percent, wind energy has been the largest source of new electricity generation for the past decade. Typically, an offshore wind farm has a medium voltage ac (MVac) grid that collects power from individual wind turbines. Since the output voltage of a wind turbine is too low (i.e., typically 400 690 V) to be connected to the MVac grid (i.e., 20 40 kV), a heavy line-frequency transformer is used to step up the individual turbines output voltage to the MV level. To eliminate the need for bulky MVac transformers, researchers are gravitating towards the idea of replacing the MVac grid with a medium voltage dc (MVdc) grid, so that MV step-up transformers are replaced by MV step-up power electronic converters that operate at the medium frequency range with much lower size and weight. This dissertation proposes a class of modular step-up transformerless MV SiC-based power converters with soft-switching capability for wind energy conversion systems with MVdc grid. This dissertation consists of two parts: the first part focuses on the development of two novel groups of step-up isolated dc-dc MV converters that utilize various step-up resonant circuits and soft-switched high voltage gain rectifier modules. An integrated magnetic design approach is also presented to combine several magnetic components together in the modular high voltage gain rectifiers. The second part of this dissertation focuses on the development of several three-phase ac-dc step-up converters with integrated active power factor correction. In particular, a bridgeless input ac-dc rectifier is also proposed to combine with the devised step-up transformerless dc-dc converters (presented in the first part) to form the three-phase soft-switched ac-dc step-up voltage conversion unit. In each of the presented modular step-up converter configurations, variable frequency control is used to regulate the output dc voltage of each converter module. The operating principles and characteristics of each presented converter are provided in detail. The feasibility and performance of all the power converter concepts presented in this dissertation are verified through simulation results on megawatts (MW) design examples, as well as experimental results on SiC-based laboratory-scale proof-of-concept prototypes

Soft-Switched Step-Up Medium Voltage Power Converters

With a ten-year average annual growth rate of 19 percent, wind energy has been the largest source of new electricity generation for the past decade. Typically, an offshore wind farm has a medium voltage ac (MVac) grid that collects power from individual wind turbines. Since the output voltage of a wind turbine is too low (i.e., typically 400 690 V) to be connected to the MVac grid (i.e., 20 40 kV), a heavy line-frequency transformer is used to step up the individual turbines output voltage to the MV level. To eliminate the need for bulky MVac transformers, researchers are gravitating towards the idea of replacing the MVac grid with a medium voltage dc (MVdc) grid, so that MV step-up transformers are replaced by MV step-up power electronic converters that operate at the medium frequency range with much lower size and weight. This dissertation proposes a class of modular step-up transformerless MV SiC-based power converters with soft-switching capability for wind energy conversion systems with MVdc grid. This dissertation consists of two parts: the first part focuses on the development of two novel groups of step-up isolated dc-dc MV converters that utilize various step-up resonant circuits and soft-switched high voltage gain rectifier modules. An integrated magnetic design approach is also presented to combine several magnetic components together in the modular high voltage gain rectifiers. The second part of this dissertation focuses on the development of several three-phase ac-dc step-up converters with integrated active power factor correction. In particular, a bridgeless input ac-dc rectifier is also proposed to combine with the devised step-up transformerless dc-dc converters (presented in the first part) to form the three-phase soft-switched ac-dc step-up voltage conversion unit. In each of the presented modular step-up converter configurations, variable frequency control is used to regulate the output dc voltage of each converter module. The operating principles and characteristics of each presented converter are provided in detail. The feasibility and performance of all the power converter concepts presented in this dissertation are verified through simulation results on megawatts (MW) design examples, as well as experimental results on SiC-based laboratory-scale proof-of-concept prototypes

Soft-Switched Step-Up Medium Voltage Power Converters

With a ten-year average annual growth rate of 19 percent, wind energy has been the largest source of new electricity generation for the past decade. Typically, an offshore wind farm has a medium voltage ac (MVac) grid that collects power from individual wind turbines. Since the output voltage of a wind turbine is too low (i.e., typically 400 690 V) to be connected to the MVac grid (i.e., 20 40 kV), a heavy line-frequency transformer is used to step up the individual turbines output voltage to the MV level. To eliminate the need for bulky MVac transformers, researchers are gravitating towards the idea of replacing the MVac grid with a medium voltage dc (MVdc) grid, so that MV step-up transformers are replaced by MV step-up power electronic converters that operate at the medium frequency range with much lower size and weight. This dissertation proposes a class of modular step-up transformerless MV SiC-based power converters with soft-switching capability for wind energy conversion systems with MVdc grid. This dissertation consists of two parts: the first part focuses on the development of two novel groups of step-up isolated dc-dc MV converters that utilize various step-up resonant circuits and soft-switched high voltage gain rectifier modules. An integrated magnetic design approach is also presented to combine several magnetic components together in the modular high voltage gain rectifiers. The second part of this dissertation focuses on the development of several three-phase ac-dc step-up converters with integrated active power factor correction. In particular, a bridgeless input ac-dc rectifier is also proposed to combine with the devised step-up transformerless dc-dc converters (presented in the first part) to form the three-phase soft-switched ac-dc step-up voltage conversion unit. In each of the presented modular step-up converter configurations, variable frequency control is used to regulate the output dc voltage of each converter module. The operating principles and characteristics of each presented converter are provided in detail. The feasibility and performance of all the power converter concepts presented in this dissertation are verified through simulation results on megawatts (MW) design examples, as well as experimental results on SiC-based laboratory-scale proof-of-concept prototypes

Development of Efficient Soft Switching Synchronous Buck Converter Topologies for Low Voltage High Current Applications

Switched mode power supplies (SMPS) have emerged as the popular candidate in all the power processing applications. The demand is soaring to design high power density converters. For reducing the size, weight, it is imperative to channelize the power at high switching frequency. High switching frequency converters insist upon soft switching techniques to curtail the switching losses. Several soft switching topologies have been evolved in the recent years. Nowadays, the soft switching converters are vastly applied modules and the demand is increasing for high power density and high efficiency modules by minimizing the conduction and switching losses. These modules are generally observed in many applications such as laptops, desktop processors for the enhancement of the battery life time. Apart from these applications, solar and spacecraft applications demand is increasing progressively for stressless and more efficient modules for maximizing the storage capacity which inturn enhances the power density that improves the battery life to supply in the uneven times. Modern trends in the consumer electronic market focus increases in the demand of lower voltage supplies. Conduction losses are significantly reduced by synchronous rectifiers i.e., MOSFET’s are essentially used in many of the low voltage power supplies. Active and passive auxiliary circuits are used in tandem with synchronous rectifier to diminish the crucial loss i.e., switching loss and also it minimizes the voltage and current stresses of the semiconductor devices. The rapid progress in the technology and emerging portable applications poses serious challenges to power supply design engineers for an efficient power converter design at high power density. The primary aim is to design and develop high efficiency, high power density topologies like: buck, synchronous buck and multiphase buck converters with the integration of soft switching techniques to minimize conduction and switching losses sustaining the voltage and current stresses within the tolerable range. In this work, two ZVT-ZCT PWM synchronous buck converters are introduced, one with active auxiliary circuit and the other one with passive auxiliary circuit. The operating principle and comprehensive steady state analysis of the ZVT-ZCT PWM synchronous buck converters are presented. The converters are designed to have high efficiency and low voltage that is suitable for high power density application. The semiconductor devices used in the topologies in addition to the main switch operate with soft switching conditions. The viii Abstract topologies proposed render a large overall efficiency in contrast to the contemporary topologies. In addition the circuit’s size is less, reliable and have high performance-cost ratio. The new generation microprocessor demands the features such as low voltage, high current, high power density and high efficiency etc., in the design of power supplies. The supply voltage for the future generation microprocessors must be low, in order to decrease the power consumption. The voltage levels are dripping to a level even less than 0.7V, and the power consumption increases as there is an increase in the current requirement for the processor. In order to meet the demands of the new generation microprocessor power supply, a soft switching multiphase PWM synchronous buck converter is proposed. The losses in the proposed topology due to increasing components are pared down by the proposed soft switching technique. The proposed converters in this research work are precisely described by the mathematical modelling and their operational modes. The practicality of the proposed converters for different applications is authenticated by their simulation and experimental results

High power high frequency DC-DC converter topologies for use in off-line power supplies

The development of a DC-DC converter for use in a proposed range of one to ten kilowatt off-line power supplies is presented. The converter makes good use of established design practices and recent technical advances. The thesis begins with a review of traditional design practices, which are used in the design of a 3kW, 48V output DC-DC converter, as a bench-mark for evaluation of recent technical advances. Advances evaluated include new converter circuits, control techniques, components, and magnetic component designs. Converter circuits using zero voltage switching (ZVS) transitions offer significant advantages for this application. Of the published converters which have ZVS transitions the phase shift controlled full bridge converter is the most suitable, and assessments of variations on this circuit are presented. During the course of the research it was realised that the ZVS range of one leg of the phase shift controlled full bridge converter could be extended by altering the switching pattern, and this new switching pattern is proposed. A detailed analysis of phase shift controlled full bridge converter operation uncovers a number of operational findings which give a better and more complete understanding of converter operation than hitherto published. Converter design equations and guidelines are presented and the effects of the new improvement are investigated by an approximate analysis. Computer simulations using PSPICE2 are carried out to predict converter performance. A prototype converter design, construction details and test results are given. The results obtained compare well to the predicted performance and confirm the advantages of the new switching pattern

Resonance mode power supplies with power factor correction

There is an increasing need for AC-DC converters to draw a pure sinusoidal current at near unity power factor from the AC mains. Most conventional power factor correcting systems employ PWM techniques to overcome the poor power factor being presented to the mains. However, the need for smaller and lighter power processing equipment has motivated the use of higher internal conversion frequencies in the past. In this context, resonant converters are becoming a viable alternative to the conventional PWM controlled power supplies. The thesis presents the implementation of active power factor correction in power supplies, using resonance mode techniques. It reviews the PWM power factor correction circuit topologies previously used. The possibility of converting these PWM topologies to resonant mode versions is discussed with a critical assessment as to the suitability of the semiconductor switching devices available today for deployment in these resonant mode supplies. The thesis also provides an overview of the methods used to model active semiconductor devices. The computer modelling is done using the PSpice microcomputer simulation program. The modifications that are needed to the built in MOSFET model in PSpice, when modeling high frequency circuits is discussed. A new two transistor model which replicates the action of a OTO thyristor is also presented. The new model enables the designer to estimate the device parameters with ease by adopting a short calculation and graphical design procedure, based on the manufacturer's data sheets. The need for a converter with a high efficiency, larger power/weight ratio, high input power factor with reduced line current distortion and reduced cost has led to the development of a new resonant mode converter topology, for power processing. The converter presents a near resistive load to the mains thus ensuring a high input power factor, while providing a stabilised de voltage at the output with a small lOOHz ripple. The supply is therefore ideal for preregulation applications. A description of the modes of operation and the analysis of the power circuit are included in the thesis. The possibility of using the converter for low output voltage applications is also discussed. The design of a 300W, 80kHz prototype model of this circuit is presented in the thesis. The design of the isolation transformer and other magnetic components are described in detail. The selection of circuit components and the design and implementation of the variable frequency control loop are also discussed. An evaluation of the experimental and computer simulated results obtained from the prototype model are included in the presentation. The thesis further presents a zero-current switching quasi-resonant flyback circuit topology with power factor correction. The reasons for using this topology for off-line power conversion applications are discussed. The use of a cascoded combination of a bipolar power transistor and two power MOSFETs i~ the configuration has enabled the circuit to process moderate levels of power while simultaneously switching at high frequencies. This fulfils the fundamental precondition for miniaturisation. It also provides a well regulated DC output voltage with a very small ripple while maintaining a high input power factor. The circuit is therefore ideal for use in mobile applications. A preliminary design of the above circuit, its analysis using PSpice, the design of the control circuit, current limiting and overcurrent protection circuitry and the implementation of closed-loop control are all included in the thesis. The experimental results obtained from a bread board model is also presented with an evaluation of the circuit performance. The power factor correction circuit is finally installed in this supply and the overall converter performance is assessed

Analysis and design of a high frequency induction-heating system

Includes bibliographical references.Advances in power electronic semiconductor technology are making high frequency converters for induction heating more feasible at power levels up to 50kW. This research presents the development and analysis of a solid-state induction-heating system, operating directly off single-phase mains frequency, which enables optimum and efficient operation over a frequency range of 80kHz to 200kHz. The system essentially comprises a DC-DC converter configured as a controlled current source, which feeds a load resonant DC-AC inverter, driving a parallel resonant load circuit. The load circuit comprises an induction-heating coil and a reactive power compensating capacitor. The systems active switching elements comprise power MOSFET's but can be extended to almost any other controlled power devices such as IGBT's, BJT's, SCR's, GTO's or SIT's. An automatic frequency control system ensures that the DC-AC inverter drives the load at its resonant frequency, thereby achieving zero voltage switching of the power semiconductors. This operating mode always ensures maximum power transfer to the load as well as maximum operating efficiency of the DC-AC inverter. Driving the load at resonance presents an essentially resistive load to the DC-DC converter, thereby reducing the losses associated with a reactive load. A compact circuit layout combined with this optimum mode of operation eliminates the need for any snubber circuit components in both the DC-DC and DC-AC converters at this power level. An overview into various applications and technologies of induction-heating is presented in this research. A detailed analysis of the induction-heating coil and work- piece are presented in order to aid the design of the load circuit. The induction-heating technology overview presents various induction-heating power sources, discussing the configurations of various topologies. A brief mathematical analysis is used to describe the operation of power electronic converters employed in the induction-heating system developed for this research. The parallel resonant induction-heating load circuit is characterised mathematically, allowing for the determination of the optimum operating conditions. This is followed by a simulation analysis, which is used to gain insight into the problem of frequency control. The frequency control system is modelled and the steady-state error response evaluated under different input conditions. Experimental results on the system implemented, based on operating waveforms and efficiency measurements of the solid-state induction-heating system are presented along with recommendations for future work. The implemented power source was tested at a maximum power of 2.3kW at 151kHz. A system efficiency of 86% at 1.3kW was measured when operating at 138kHz. This design however, provides for scaling to power levels up to 50kW. The induction-heating system's frequency tracking capability is evaluated by heating a steel work-piece through its Curie transition temperature. The induction-heating system is used to heat a 26mm x 35mm stainless-steel billet (work-piece) to 1200°C in 130 seconds using the calculated power of 1.35kW

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