Efficient, High Power Density, Modular Wide Band-gap Based Converters for Medium Voltage Application

Recent advances in semiconductor technology have accelerated developments in medium-voltage direct-current (MVDC) power system transmission and distribution. A DC-DC converter is widely considered to be the most important technology for future DC networks. Wide band-gap (WBG) power devices (i.e. Silicon Carbide (SiC) and Gallium Nitride (GaN) devices) have paved the way for improving the efficiency and power density of power converters by means of higher switching frequencies with lower conduction and switching losses compared to their Silicon (Si) counterparts. However, due to rapid variation of the voltage and current, di/dt and dv/dt, to fully utilize the advantages of the Wide-bandgap semiconductors, more focus is needed to design the printed circuit boards (PCB) in terms of minimizing the parasitic components, which impacts efficiency. The aim of this dissertation is to study the technical challenges associated with the implementation of WBG devices and propose different power converter topologies for MVDC applications. Ship power system with MVDC distribution is attracting widespread interest due to higher reliability and reduced fuel consumption. Also, since the charging time is a barrier for adopting the electric vehicles, increasing the voltage level of the dc bus to achieve the fast charging is considered to be the most important solution to address this concern. Moreover, raising the voltage level reduces the size and cost of cables in the car. Employing MVDC system in the power grid offers secure, flexible and efficient power flow. It is shown that to reach optimal performance in terms of low package inductance and high slew rate of switches, designing a PCB with low common source inductance, power loop inductance, and gate-driver loop are essential. Compared with traditional power converters, the proposed circuits can reduce the voltage stress on switches and diodes, as well as the input current ripple. A lower voltage stress allows the designer to employ the switches and diodes with lower on-resistance RDS(ON) and forward voltage drop, respectively. Consequently, more efficient power conversion system can be achieved. Moreover, the proposed converters offer a high voltage gain that helps the power switches with smaller duty-cycle, which leads to lower current and voltage stress across them. To verify the proposed concept and prove the correctness of the theoretical analysis, the laboratory prototype of the converters using WBG devices were implemented. The proposed converters can provide energy conversion with an efficiency of 97% feeding the nominal load, which is 2% more than the efficiency of the-state-of-the-art converters. Besides the efficiency, shrinking the current ripple leads to 50% size reduction of the input filter inductors

A Comprehensive Assessment of Multiwinding Transformer-Based DC-DC Converters

Multiwinding-Transfomer-based (MTB) DC-DC converter did emerge in the last 25 years as an interesting possibility to connect several energy systems and/or to offer higher power density because of the reduction of transformer core material and reduction of power converter stages. MTB DC-DC converters can be considered as an interesting compromise between non-modular and a modular DC-DC converter since they are themselves modular in the construction. This eventually leads to some fault-tolerant possibilities since the multiwinding transformer (MWT) connects multiples ports and if one of them is not working anymore and it can be isolated, the others might still continue operating. Unfortunately, it is exactly the MWT that creates most of the technical challenges of this class of DC-DC converters because of the cross-coupling effects among the cells which make especially the resonant-topology very challenging to be designed. This paper reviews the history of the MTB DC-DC and then provides a classification of them, comparing them with Figure of Merits (FOM) and focusing on which is the maximum possible number of windings and which are the most suited magnetic core types. The problems coming from cross-coupling and the possible fault-tolerant operation are analysed with the help of simulation and experimental results

New Topologies and Advanced Control of Power Electronic Converters for Renewable Energy based Microgrids

Solar energy-based microgrids are increasingly promising due to their many features, such as being environmentally friendly and having low operating costs. Power electronic converters, filters, and transformers are the key components to integrate the solar photovoltaic (PV) systems with the microgrids. The power electronic converters play an important role to reduce the size of the filter circuit and eliminate the use of the bulky and heavy traditional power frequency step-up transformer. These power converters also play a vital role to integrate the energy storage systems such as batteries and the superconducting magnetic energy storage (SMES) unit in a solar PV power-based microgrid. However, the performance of these power converters depends upon the switching technique and the power converter configuration. The switching techniques can improve the power quality, i.e. lower total harmonic distortion at the converter output waveform, reduce the converter power loss, and can effectively utilize the dc bus voltage, which helps to improve the power conversion efficiency of the power electronic converter. The power converter configuration can reduce the size of the power converter and make the power conversion system more efficient. In addition to the advanced switching technique, a supervisory control can also be integrated with these power converters to ensure the optimal power flow within the microgrid. First, this thesis reviews different existing power converter topologies with their switching techniques and control strategies for the grid integration of solar PV systems. To eliminate the use of the bulky and heavy line frequency step-up transformer to integrate solar PV systems to medium voltage grids, the high frequency magnetic linkbased medium voltage power converter topologies are discussed and compared based on their performance parameters. Moreover, switching and conduction losses are calculated to compare the performance of the switching techniques for the magnetic-linked power converter topologies. In this thesis, a new pulse width modulation technique has been proposed to integrate the SMES system with the solar PV system-based microgrid. The pulse width modulation technique is designed to provide reactive power into the network in an effective way. The modulation technique ensures lower total harmonic distortion (THD), lower switching loss, and better utilization of dc-bus voltage. The simulation and experimental results show the effectiveness of the proposed pulse width modulation technique. In this thesis, an improved version of the previously proposed switching technique has been designed for a transformer-less PV inverter. The improved switching technique can ensure effective active power flow into the network. A new switching scheme has been proposed for reactive power control to avoid unnecessary switching faced by the traditional switching technique in a transformer-less PV inverter. The proposed switching technique is based on the peak point value of the grid current and ensures lower switching loss compared to other switching techniques. In this thesis, a new magnetic-linked multilevel inverter has been designed to overcome the issues faced by the two-level inverters and traditional multilevel inverters. The proposed multilevel inverter utilizes the same number of electronic switches but fewer capacitors compared to the traditional multilevel inverters. The proposed multilevel inverter solves the capacitor voltage balancing and utilizes 25% more of the dc bus voltage compared to the traditional multilevel inverter, which reduces the power rating of the dc power source components and also extends the input voltage operating range of the inverter. An improved version magnetic-linked multilevel inverter is proposed in this thesis with a model predictive control technique. This multilevel inverter reduces both the number of switches and capacitors compared to the traditional multilevel inverter. This multilevel inverter also solves the capacitor voltage balancing issue and utilizes 50% more of the dc bus voltage compared to the traditional multilevel inverter. Finally, an energy management system has been designed for the developed power converter and control to achieve energy resiliency and minimum operating cost of the microgrid. The model predictive control-based energy management system utilizes the predicted load data, PV insolation data from web service, electricity price data, and battery state of charge data to select the battery charging and discharging pattern over the day. This model predictive control-based supervisory control with the advanced power electronic converter and control makes the PV energy-based microgrid more efficient and reliable

MODELING AND CONTROL OF DIRECT-CONVERSION HYBRID SWITCHED-CAPACITOR DC-DC CONVERTERS

Efficient power delivery is increasingly important in modern computing, communications, consumer and other electronic systems, due to the high power demand and thermal concerns accompanied by performance advancements and tight packaging. In pursuit of high efficiency, small physical volume, and flexible regulation, hybrid switched-capacitor topologies have emerged as promising candidates for such applications. By incorporating both capacitors and inductors as energy storage elements, hybrid topologies achieve high power density while still maintaining soft charging and efficient regulation characteristics. However, challenges exist in the hybrid approach. In terms of reliability, each flying capacitor should be maintained at a nominal `balanced\u27 voltage for robust operation (especially during transients and startup), complicating the control system design. In terms of implementation, switching devices in hybrid converters often need complex gate driving circuits which add cost, area, and power consumption. This dissertation explores techniques that help to mitigate the aforementioned challenges. A discrete-time state space model is derived by treating the hybrid converter as two subsystems, the switched-capacitor stage and the output filter stage. This model is then used to design an estimator that extracts all flying capacitor voltages from the measurement of a single node. The controllability and observability of the switched-capacitor stage reveal the fundamental cause of imbalance at certain conversion ratios. A new switching sequence, the modified phase-shifted pulse width modulation, is developed to enable natural balance in originally imbalanced scenarios. Based on the model, a novel control algorithm, constant switch stress control, is proposed to achieve both output voltage regulation and active balance with fast dynamics. Finally, the design technique and test result of an integrated hybrid switched-capacitor converter are reported. A proposed gate driving strategy eliminates the need for external driving supplies and reduces the bootstrap capacitor area. On-chip mixed signal control ensures fast balancing dynamics and makes hard startup tolerable. This prototype achieves 96.9\% peak efficiency at 5V:1.2V conversion and a startup time of 12$\mu s$, which is over 100 times faster than the closest prior art. With the modeling, control, and design techniques introduced in this dissertation, the application of hybrid switched-capacitor converters may be extended to scenarios that were previously challenging for them, allowing enhanced performance compared to using traditional topologies. For problems that may require future attention, this dissertation also points to possible directions for further improvements

Dual-frequency single-inductor multiple-output (DF-SIMO) power converter topology for SoC applications

Modern mixed-signal SoCs integrate a large number of sub-systems in a single nanometer CMOS chip. Each sub-system typically requires its own independent and well-isolated power supply. However, to build these power supplies requires many large off-chip passive components, and thus the bill of material, the package pin count, and the printed circuit board area and complexity increase dramatically, leading to higher overall cost. Conventional (single-frequency) Single-Inductor Multiple-Output (SIMO) power converter topology can be employed to reduce the burden of off-chip inductors while producing a large number of outputs. However, this strategy requires even larger off-chip output capacitors than single-output converters due to time multiplexing between the multiple outputs, and thus many of them suffer from cross coupling issues that limit the isolation between the outputs. In this thesis, a Dual-Frequency SIMO (DF-SIMO) buck converter topology is proposed. Unlike conventional SIMO topologies, the DF-SIMO decouples the rate of power conversion at the input stage from the rate of power distribution at the output stage. Switching the input stage at low frequency (~2 MHz) simplifies its design in nanometer CMOS, especially with input voltages higher than 1.2 V, while switching the output stage at higher frequency enables faster output dynamic response, better cross-regulation, and smaller output capacitors without the efficiency and design complexity penalty of switching both the input and output stages at high frequency. Moreover, for output switching frequency higher than 100 MHz, the output capacitors can be small enough to be integrated on-chip. A 5-output 2-MHz/120-MHz design in 45-nm CMOS with 1.8-V input targeting low-power microcontrollers is presented as an application. The outputs vary from 0.6 to 1.6 V, with 4 outputs providing up to 15 mA and one output providing up to 50 mA. The design uses single 10-uH off-chip inductor, 2-nF on-chip capacitor for each 15-mA output and 4.5-nF for the 50-mA output. The peak efficiency is 73%, Dynamic Voltage Scaling (DVS) is 0.6 V/80 ns, and settling time is 30 ns for half-to-full load steps with no observable overshoot/undershoot or cross-coupling transients. The DF-SIMO topology enables realizing multiple efficient power supplies with faster dynamic response, better cross-regulation, and lower overall cost compared to conventional SIMO topologies