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

Development of Improved Performance Switchmode Converters for Critical Load Applications

Emerging portable applications and the rapid advancement of technology have posed rigorous challenges to power engineers for an efficient power delivery at high power density. The foremost objectives are to develop high efficiency, high power density topologies such as: buck, synchronous buck and multiphase buck converters, with the implementation of soft switching technology to reduce switching losses maintaining voltage and current stresses within the permissible range. Demand of low voltage power supply for telecom system leads to narrow duty cycle which compels to increase operating switching frequency. Design of conventional buck converter under narrow duty cycle is quite objectionable since it leads to poor utilization of components as well as it degrades the system efficiency. A high switching frequency operation reduces the switch conduction time that leads to large increase in switching losses and increases the control complexity. Therefore, duty cycle has to be extended and at the same time switching losses have to be minimized. Transformer based topology can be used to extend the duty cycle. But to reduce switching losses soft switching techniques should be implemented. An isolated buck converter with simple clamp capacitor scheme is proposed to reduce switching losses and to extend duty cycle by optimizing the turn ratio. Extended duty cycle impose limit on dead time. Dead time has to be controlled with respect to duty cycle to reduce body diode conduction loss and to avoid the shoot through conditions in our proposed topology. The proposed clamp capacitor scheme control the dead time as well as provide better efficiency with reduction in switching losses maintaining ripples within the allowable range

Performance Improvement of AC-DC Power Factor Correction Converters For Distributed Power System

In present situation, the increase in the utilization of computers, laptops,uninterruptable power supplies, telecom and bio-medical equipments has become uncontrollable as its growth is rising exponentially. Hence, increase in functionality of such equipments leads to the higher power consumption and low power density which provided a large market to distributed power systems (DPS). The development of these DPS posed challenges to power engineers for an efficient power delivery with stringent regulating standards; this is the motivation and driving force of this research work. The objective is to minimize the switching losses of front-end converters employed in DPS, with the primary aim of achieving nearly unity power factor operation of converters.Single-phase and three-phase rectifiers are increasingly used in the field of alternating current – direct current (AC-DC) power converters as front-end converters in DPS. For power factor correction (PFC) stage, conventional single-phase AC-DC PFC boost converter is the most suitable topology because of its inherent advantages. These PFC boost converters exhibit poor dynamic regulation of output voltage owing to low pass filter in the voltage feedback loop. Research effort has been made to mitigate this problem of AC-DC PFC boost converters. An extended pulse width modulation switching technique has been investigated and proposed especially for single-phase and three-phase AC-DC PFC boost converters to improve the dynamic response of output voltage during transient periods

An Interleaved Soft Switched High Step-Up Boost Converter With High Power Density for Renewable Energy Applications

In this article, a novel soft switched interleaved boost structure with a simple auxiliary circuit is proposed which is suitable for stand-alone loads or ac grid applications. In this topology, coupled inductors and switched capacitor cells of parallel modules are merged to obtain high voltage conversion ratio. The converter also has the capability of adding extra switched capacitor cells to attain very high voltage gain. To provide soft-switching condition in the wide range of output power, a new zero-voltage transition auxiliary circuit is employed which is responsible for soft switching of both phases and benefits from low conduction losses, the minimum number of semiconductor elements, and only one auxiliary gate-driver. These merits provide very high efficiency at both full-load and light loads. More importantly, no auxiliary magnetic components are utilized by taking advantage of the leakage inductance of coupled inductors for the resonant network. All semiconductor components operate under soft switching alleviating the reverse recovery problem and switching losses. Besides, the converter benefits from common ground between input and output which simplify voltage feedback. The experimental results of the interleaved converter prototype with 400-V output voltage at 400 W and 100 kHz switching frequency are provided. The full load efficiency of 98% was achieved and the power density was observed 1.9 W/Cm3

Low Voltage Regulator Modules and Single Stage Front-end Converters

Evolution in microprocessor technology poses new challenges for supplying power to these devices. To meet demands for faster and more efficient data processing, modem microprocessors are being designed with lower voltage implementations. More devices will be packed on a single processor chip and the processors will operate at higher frequencies, exceeding 1GHz. New high-performance microprocessors may require from 40 to 80 watts of power for the CPU alone. Load current must be supplied with up to 30A/µs slew rate while keeping the output voltage within tight regulation and response time tolerances. Therefore, special power supplies and Voltage Regulator Modules (VRMs) are needed to provide lower voltage with higher current and fast response. In the part one (chapter 2,3,4) of this dissertation, several low-voltage high-current VRM technologies are proposed for future generation microprocessors and ICs. The developed VRMs with these new technologies have advantages over conventional ones in terms of efficiency, transient response and cost. In most cases, the VRMs draw currents from DC bus for which front-end converters are used as a DC source. As the use of AC/DC frond-end converters continues to increase, more distorted mains current is drawn from the line, resulting in lower power factor and high total harmonic distortion. As a branch of active Power factor correction (PFC) techniques, the single-stage technique receives particular attention because of its low cost implementation. Moreover, with continuously demands for even higher power density, switching mode power supply operating at high-frequency is required because at high switching frequency, the size and weight of circuit components can be remarkably reduced. To boost the switching frequency, the soft-switching technique was introduced to alleviate the switching losses. The part two (chapter 5,6) of the dissertation presents several topologies for this front-end application. The design considerations, simulation results and experimental verification are discussed

Robust Control of Wide Bandgap Power Electronics Device Enabled Smart Grid

abstract: In recent years, wide bandgap (WBG) devices enable power converters with higher power density and higher efficiency. On the other hand, smart grid technologies are getting mature due to new battery technology and computer technology. In the near future, the two technologies will form the next generation of smart grid enabled by WBG devices. This dissertation deals with two applications: silicon carbide (SiC) device used for medium voltage level interface (7.2 kV to 240 V) and gallium nitride (GaN) device used for low voltage level interface (240 V/120 V). A 20 kW solid state transformer (SST) is designed with 6 kHz switching frequency SiC rectifier. Then three robust control design methods are proposed for each of its smart grid operation modes. In grid connected mode, a new LCL filter design method is proposed considering grid voltage THD, grid current THD and current regulation loop robust stability with respect to the grid impedance change. In grid islanded mode, µ synthesis method combined with variable structure control is used to design a robust controller for grid voltage regulation. For grid emergency mode, multivariable controller designed using H infinity synthesis method is proposed for accurate power sharing. Controller-hardware-in-the-loop (CHIL) testbed considering 7-SST system is setup with Real Time Digital Simulator (RTDS). The real TMS320F28335 DSP and Spartan 6 FPGA control board is used to interface a switching model SST in RTDS. And the proposed control methods are tested. For low voltage level application, a 3.3 kW smart grid hardware is built with 3 GaN inverters. The inverters are designed with the GaN device characterized using the proposed multi-function double pulse tester. The inverter is controlled by onboard TMS320F28379D dual core DSP with 200 kHz sampling frequency. Each inverter is tested to process 2.2 kW power with overall efficiency of 96.5 % at room temperature. The smart grid monitor system and fault interrupt devices (FID) based on Arduino Mega2560 are built and tested. The smart grid cooperates with GaN inverters through CAN bus communication. At last, the three GaN inverters smart grid achieved the function of grid connected to islanded mode smooth transitionDissertation/ThesisDoctoral Dissertation Electrical Engineering 201

Optimization of Nonlinear Switch Cells for Switching Converters

Switch cells consist of an array of power switches and passive components which can replace the main switches alone in many power topologies, allowing reduced switching loss without altering the power topology directly. This thesis discusses the development of a switch cell topology that utilizes a saturable resonant inductor to reduce the size and power loss of the cell. Additionally, the cell transfers energy stored in the inductor into a capacitor for efficient energy storage during the cell\u27s conduction region. This energy is then transferred back to the system when the cell turns off, thus reducing the total switching energy

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

Analysis and design of a dual series-resonant DC-DC converter

DC-DC conversion systems are vital components in DC distribution systems, renewable energy generation systems, telecommunication systems, and portable electronics devices. The extensive applications of DC-DC converter have resulted in continuous improvement in the topologies and control methods in these converters. The challenge is to build a converter that improves factors such as efficiency of conversion and power density with a simple topology, which incorporates simplified switching and control schemes and fewer numbers of active and passive components to reduce the manufacturing cost. This thesis addresses this challenge by proposing an alternative topology of a DC-DC converter based on dual series-resonant circuits. The proposed topology operates under zero voltage switching (ZVS) and zero current switching (ZCS) conditions to reduce the switching losses. It achieves two degrees of freedom (i.e., duty ratio and switching frequency) to control the output voltage of the converter, which results in both step-down and step-up voltage conversions. The number of active components is limited to two semiconductor switches and two rectifying diodes, which reduces the manufacturing cost of the converter. Detailed analytical analysis is carried out using the extended describing function methodology to characterize the steady state and small signal operation of the converter. Small-signal transfer functions are developed and used to propose a simple closed-loop control scheme to control the output voltage of the converter. An experimental 10 V, 40 W prototype of the proposed converter is built and tested to investigate its operation and confirm its features. The improvement in the efficiency of the converter and power transfer capability of the proposed dual series-resonant converter compared with the traditional single series-resonant circuit, which is used in the interleaved topologies are experimentally verified. In addition, soft switching operation of the converter is realized and a simple control scheme is developed to control the output voltage of the converter. A detailed and step-by-step design procedure is developed, which can be used to customize the design of the converter for different levels of power and voltage. It is shown that the proposed dual series-resonant DC-DC converter provides significant improvement regarding power density, efficiency of power conversion, simplicity of switching and control schemes, and reduced number of converter components resulting in a low cost and compact converter