Design considerations for a high-power dual active bridge DC-DC converter with galvanically isolated transformer

Multi-megawatt scale isolated DC-DC converters are likely to become increasingly popular as means to interconnect the MVDC grids of different voltage levels. Threephase dual active bridge DC-DC (3DAB) converters operating with the zero-voltage switching (ZVS) is a promising candidate for the target multi-megawatt application. This paper presents a systematic approach of the design considerations for a 3DAB converter. Firstly, the use of snubber capacitors in medium voltage and medium frequency operating conditions is proposed. Snubber capacitor influence on turn-off current levels and ZVS operating range are introduced and analyzed. In addition, details of thermal management design are introduced. It is established through power loss analysis that the proposed design method reduces the semiconductor losses substantially at full load conditions. Finally, the proposed method has been validated from a 10kW simulation model using PLECS software package

Optimal design methodology of zero-voltage-switching full-bridge pulse width modulated converter for server power supplies based on self-driven synchronous rectifier performance

In this paper, high-efficiency design methodology of a zero-voltage-switching full-bridge (ZVS-FB) pulse width modulation (PWM) converter for server-computer power supply is discussed based on self-driven synchronous rectifier (SR) performance. The design approach focuses on rectifier conduction loss on the secondary side because of high output current application. Various-number parallel-connected SRs are evaluated to reduce high conduction loss. For this approach, the reliability of gate control signals produced from a self-driver is analyzed in detail to determine whether the converter achieves high efficiency. A laboratory prototype that operates at 80 kHz and rated 1 kW/12 V is built for various-number parallel combination of SRs to verify the proposed theoretical analysis and evaluations. Measurement results show that the best efficiency of the converter is 95.16%. © 2016 KIPE

Review of Selected Multi-Element Resonant Topologies

The paper deals with an analysis andcomparison of multi-element resonant topologies. Thesuperior performance of the investigated convertersprovides inherent current protection and very lowcirculating energy. The converter consists of two resonanttanks and HF transformer in case of the LCTLC topology.The paper shows the design of the resonant elements. Theconverters can achieve zero current switching (ZCS) andzero voltage switching (ZVS) conditions for the primary andsecondary-side of the device respectively. The convertersachieve high values of power density and efficiency up to96 % at the full load. The paper includes the basicequations, analysis and simulation of the chosen topologies(LCTLC, LCLCL, LCL2C2)

Optimization of 8-Plate Multi-Resonant Coupling Structure Using Class-E\u3csup\u3e2\u3c/sup\u3e Based Capacitive-Wireless Power Transfer System

Capacitive-wireless power transfer (CPT) effectively charges battery-powered devices without a physical contact. It is an alternative to inductive-wireless power transfer (IPT) which is available in the present market. Compared with IPT, CPT offers flexibility in designing the coupling section. Because of its flexibility, CPT utilizes various coupling methods to enhance the coupling capacitance. Misalignment is a common issue in any WPT system. Among IPT and CPT, IPT has better performance for misalignments, but it requires bulk and expensive ferrite core to attain a high coupling coefficient. This work focuses on designing a CPT system to minimize the impact of misalignments. In this research, a novel 8-plate multi-resonant Class-E2 CPT system is developed to improve the performance of the CPT system for misalignments. The proposed CPT model expands the resonant frequency band, which results in better performance for misalignments compared with the regular 4-plate CPT system. The 8-plate coupling structure is designed to charge a 100 Ah drone battery. For this application, the coupling is formed when the drone lands on the capacitive- wireless charging pad. This work also presents the analysis of several dielectric materials with different dielectric constants. A well-designed capacitive coupler can effectively limit harmonics during the interaction between transmitter and receiver. Also, the effect of coupling plate shape is identified on the CPT system. The hardware tests indicate the round-shaped plates have better stability in coupling capacitance with the variation in frequency. The effect of misalignments is studied through the impedance tracking of the Class-E2 power converter. Impedance plots for 50 μH, and 100 μH resonant inductors are used to determine input current peak for each case. Additionally, hardware tests are performed to study the variation of input current and output voltage for a range of frequencies. The test results indicate the efficiency at optimal impedance point for a resonant inductor with 50 μH is 8% higher compared to the CPT with a 100 μH resonant inductor which highlights the effects of the resonant inductor on efficiency. The zero-voltage-switching (ZVS) limits are also identified for varying frequencies and duty cycles. Later in this research, the optimal design of the Class-E rectifier is identified to enhance the power transfer. Several cases were considered to investigate the impact of the secondary inductor on the output voltage and the ZVS property. Hardware tests validate that under optimal conditions the efficiency of the Class-E2 based CPT system improves by 18% compared with Ar \u3e\u3c 1. Further work presents the advantages of 8-plate multi-resonant coupling for misalignments. The proposed model has a simple design procedure which enhances the power flow from the inverter to the rectifier section. The hardware results of the proposed 8-plate multi-resonant coupling show an increase in efficiency to 88.5% for the 20.8 W test, which is 18% higher than regular 4-plate coupling. Because of the wider resonant frequency band [455- 485 kHz], compared with regular 4-plate coupling, the proposed design minimized the output voltage drop by 15% for 10% misalignment. Even for large misalignments, 8-plate improves the CPT performance by 40% compared with 4-plate coupling

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

Unfolded resonant converter with current doubler structure module for welding applications

A new multiphase resonant converter arrangement with series dual phase in the primary side and parallel dual current doubler in the secondary side, operating as a phase shift controlled current source is presented. Sharing the voltage and current stress among the active and passive components with a high DC input voltage and arc current motivates this structure, which also uses WBG devices to increase the efficiency at high switching frequency. The resulting module is intended to operate in continuous and pulsating mode and can be parallelized to extend the output arc current rate.This work was funded by the Spanish Ministry of Science and the EU through the project TEC2014-52316-R: ‘Estimation and Optimal Control for Energy Conversion with Digital Devices’ ECOTRENDD

Digital control of dual-load LCLC resonant converters

The paper proposes the analysis, design and realisation of dual-output resonant LCLC converters with independent output regulation, employing a single power stage and combined PWM and frequency control. Asymmetric switching of the power devices is used to facilitate independent control of the outputs to provide +5 V and +3.3 V from a 15 V-20 V input supply over a range of load condition

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

8-Plate Multi-Resonant Coupling Using a Class-E\u3csup\u3e2\u3c/sup\u3e Power Converter For Misalignments in Capacitive Wireless Power Transfer

Misalignment is a common issue in wireless power transfer systems. It shifts the resonant frequency away from the operating frequency that affects the power flow and efficiency from the charging station to the load. This work proposes a novel capacitive wireless power transfer (CPT) using an 8-plate multi-resonant capacitive coupling to minimize the effect of misalignments. A single-active switch class-E2 power converter is utilized to achieve multi-resonance through the selection of different resonant inductors. Simulations show a widening of the resonant frequency band which offers better performance than a regular 4-plate capacitive coupling for misalignments. The hardware results of the 8-plate multi-resonant coupling show an efficiency of 88.5% for the 20.8 W test, which is 18.3% higher than that of the regular 4-plate coupling. Because of the wider resonant frequency band {455–485 kHz}, compared with the regular 4-plate coupling, the proposed design minimized the output voltage drop by 15% for a 10% misalignment. Even for large misalignments, the 8-plate performance improved by 40% compared with the 4-plate coupling