Soft-Switching Full-Bridge Topology with AC Distribution Solution in Power Converters’ Auxiliary Power Supplies

The auxiliary power supply in a power converter is a key topic in the optimization of the converter’s low-voltage electronic circuit performance. In this article, a low-voltage DC-AC soft-switching full-bridge topology, with an innovative, driven technique to achieve a zero-voltage transition, is presented and discussed. The full-bridge converter drives a high-frequency transformer (called the main transformer) that on the secondary side, distributes an AC voltage and current to the several electronic circuit’s supplies. Every power supply is composed of an HF transformer (called load transformer) that converts the AC secondary voltage of the main transformer to the voltage and current levels requested by the electronic circuit. In this paper, the operating conditions are first investigated by several simulation results. Furthermore, an actual DC-DC power converter is used as a workbench for an experimental investigation of the effectiveness of the proposed auxiliary DC-AC soft-switching topology, and the AC distribution approach, to realize the several points of load power supply requested. Finally, the advantages and drawbacks of this auxiliary power supply solution are critically discussed, providing guidelines for the power converter designer

Modeling and control of a high power soft-switched bi-directional DC/DC converter for fuel cell applications

This work presents a new high power, bi-directional, isolated dc-dc converter for a fuel cell energy management system that will be fitted into a test vehicle being built by Ford Motor Company. The work includes two parts. The first part is to propose a new topology and analyze the principles of the circuits operation. Design guidelines with detailed circuit simulations are presented to verify the feasibility of the new circuit topology. Based on the conceptual understanding of the converter, the mathematical model is also derived to design a control system that achieves soft start up and meets the performance requirements. The second part is to fabricate a 1.6 kW prototype converter in the laboratory. Using the prototype, the steady state performance of the open loop system was tested to verify the analysis and simulation results. A dual half-bridge topology is presented to implement the required power rating using the minimum number of devices. Unified zero-voltage-switching (ZVS) is achieved in either direction of power flow to eliminate switching losses for all devices, increase the efficiency of the system and reduce the electromagnetic interference (EMI). Compared to the other soft-switched dc-dc converters, neither a voltage-clamping circuit nor extra switching devices and resonant components are required in the proposed circuit for soft-switching implementation. All these new features allow efficient power conversion and compact packaging. Different start-up schemes are proposed to successfully limit the in-rush current when the converter is started in the boost mode of operation. The full control system including the start-up scheme is developed and verified using simulation results based upon the average model. A 1.6 kW prototype of the converter has been built and successfully tested under full power. The experimental results of the converter\u27s steady-state operation confirm the simulation analysis

Deploying SiC BJTs in an 800-V switched-mode power supply for hybrid & electric vehicles

An SMPS for hybrid electric vehicle and electric vehicle applications is presented. The use of SiC BJTs in the primary-side switching circuitry is investigated. Practical deployment aspects are addressed. Particular attention is given to the design of the BJT base driver stage and a bespoke turn-on switching-aid circuit. Mathematical design calculations are not presented, but the proposed circuitry is demonstrated in a 1-kW isolated-output DC-DC converter operating from 800 V and supplying 48 V at a switching frequency of 60 kHz. Full-load efficiency was evaluated at 93.3% using a calorimeter

A Resonant One-Step 325 v to 3.3-10 v DC-DC Converter with Integrated Power Stage Benefiting from High-Voltage Loss-Reduction Techniques

This work presents a self-timed resonant high-voltage (HV) dc-dc converter in HV CMOS silicon-on-insulator (SOI) with a one-step conversion from 100-325 V input down to a 3.3-10 V output, optimized for applications below 500 mW, such as IoT, smart home, and e-mobility. Unlike bulky power modules, the HV converter is fully integrated, including an on-chip power stage, with only one external inductor (10 $\mu \text{H}$ ) and capacitor (470 nF). It reaches a high power density of 752 mW/cm3, an overall peak efficiency as high as 81%, and a light-load efficiency of 73.2% at 5 V and 50 mW output. HV loss-reduction techniques are presented and experimentally confirmed to offer an efficiency improvement of more than 32%. Integrated HV insulated gate bipolar transistors (IGBTs) are discussed and implemented as an attractive alternative to conventional integrated HV power switches, resulting in 20% smaller area at lower losses

Automated Synthesis Tool for Design Optimization of Power Electronic Converters

Designers of power electronic converters usually face the challenge of having multiple performance indices that must be simultaneously optimized, such as maximizing efficiency while minimizing mass or maximizing reliability while minimizing cost. The experienced engineer applies his or her judgment to reduce the number of possible designs to a manageable number of feasible designs for which to prototype and test; thus, the optimality of this design-space reduction is directly dependent upon the experience, and expertise and biases of the designer. The practitioner is familiar with tradeoff analysis; however, simple tradeoff studies can become difficult or even intractable if multiple metrics are considered. Hence a scientific and systematic approach is needed. In this dissertation, a multi-objective optimization framework is presented as a design tool. Optimization of power electronic converters is certainly not a new subject. However, when limited to off-the-shelf components, the resulting system is really optimized only over the set of commercially available components, which may represent only a subset of the design space; the reachable space limited by available components and technologies. While this approach is suited to cost-reduce an existing design, it offers little insight into design possibilities for greenfield projects. Instead, this work uses the Technology Characterization Methods (TCM) to broaden the reachable design space by considering fundamental component attributes. The result is the specification for the components that create the optimal design rather than an evaluation of an apriori selected set of candidate components. A unique outcome of this approach is that new technology development vectors may emerge to develop optimized components for the optimized power converter. The approach presented in this work uses a mathematical descriptive language to abstract the characteristics and attributes of the components used in a power electronic converter in a way suitable for multi-objective and constrained optimization methods. This dissertation will use Technology Characterization Methods (TCM) to bridge the gap between high-level performance attributes and low-level design attributes where direct relationship between these two does not currently exist. The loss and size models for inductors, capacitors, IGBTs, MOSFETs and heat sinks will be used to form objective functions for the multi-objective optimization problem. A single phase IGBT-based inverter is optimized for efficiency and volume based on the component models derived using TCM. Comparing the obtained designs to a design, which can be made from commercial off-the-shelf components, shows that converter design can be optimized beyond what is possible from using only off-the-shelf components. A module-integrated photovoltaic inverter is also optimized for efficiency, volume and reliability. An actual converter is constructed using commercial off-the-shelf components. The converter design is chosen as close as possible to a point obtained by optimization. Experimental results show that the converter modeling is accurate. A new approach for evaluation of efficiency in photovoltaic converter is also proposed and the front-end portion of a photovoltaic converter is optimized for this efficiency, as well as reliability and volume

High-efficiency voltage source converters with silicon super-junction MOSFETs

High-efficiency power converters have the benefits of minimising energy consumption, reducing costs, and realising high power densities. The silicon super-junction (SJ) MOSFET is an attractive device for high-efficiency applications. However, its highly non-linear output capacitance and the reverse recovery properties of its intrinsic diode must be addressed when used in voltage source converters (VSCs). The research in this thesis aims at addressing these two problems and realising high efficiency. Initially, state-of-art techniques in the literature are reviewed. In order to develop a solution with simple hardware, no major auxiliary magnetic components, and no onerous timing requirements, a dual-mode switching technique is proposed. The technique is demonstrated using a SJ MOSFET based bridge-leg circuit. The hardware performance is then experimentally investigated with different power semiconductor device permutations. The transition conditions between the two switching modes do not have to be tightly set in order to maintain a high efficiency. The dual-mode switching technique is then further investigated with a current transformer (CT) arrangement embedded in the MOSFET’s gate driver circuit in order to control the profile of the MOSFET’s incoming drain current at turn on. The dual-mode switching technique, with or without a CT scheme, is shown to achieve high efficiency with minimal additional hardware.High-efficiency power converters have the benefits of minimising energy consumption, reducing costs, and realising high power densities. The silicon super-junction (SJ) MOSFET is an attractive device for high-efficiency applications. However, its highly non-linear output capacitance and the reverse recovery properties of its intrinsic diode must be addressed when used in voltage source converters (VSCs). The research in this thesis aims at addressing these two problems and realising high efficiency. Initially, state-of-art techniques in the literature are reviewed. In order to develop a solution with simple hardware, no major auxiliary magnetic components, and no onerous timing requirements, a dual-mode switching technique is proposed. The technique is demonstrated using a SJ MOSFET based bridge-leg circuit. The hardware performance is then experimentally investigated with different power semiconductor device permutations. The transition conditions between the two switching modes do not have to be tightly set in order to maintain a high efficiency. The dual-mode switching technique is then further investigated with a current transformer (CT) arrangement embedded in the MOSFET’s gate driver circuit in order to control the profile of the MOSFET’s incoming drain current at turn on. The dual-mode switching technique, with or without a CT scheme, is shown to achieve high efficiency with minimal additional hardware

Isolated and Bidirectional DC-DC Converter for Electric Vehicles

O estado da arte iniciou com a análise na literatura de topologias de conversores DC-DC. Técnicas de modulação são estudadas com vista a melhorar a eficiência de conversão, realçando as vantagens e limitações inerentes das mesmas. Após a análise da literatura, o foco projeto passou a ser a topologias de dupla ponte com dispositivos ativos e com isolamento galvânico intermédio entre as duas pontes (conhecido em inglês por dual active bridge). Algumas técnicas de modulação que permitem o funcionamento do conversor são analisadas no documento e suportadas com resultados obtidos em ambiente de simulação. O dimensionamento do transformador de potência é realizado assim como a descrição dos passos. É relizado uma análise de mercado de dispositivos de comutação com a tecnologia "Silicon Carbide" e são apresentados estimativas de perdas e eficiência de operação na utilização de transistores com a techonoloa SiC no conversor analisado. Os resultados são obtidos com recurso a simulações computacionais que através de modelos de aproximação permitem aproximar o conversor a uma situação mais proxima da real. Em termos de implementação, é esperado a implementação um circuito de comando para dois MOSFETS com tecnologia SiC com a configuração em meia ponte ligada a uma carga