Assessment of novel power electronic converters for drives applications

Phd ThesisIn the last twenty years, industrial and academic research has produced over one hundred new converter topologies for drives applications. Regrettably, most of the published work has been directed towards a single topology, giving an overall impression of a large number of unconnected, competing techniques. To provide insight into this wide ranging subject area, an overview of converter topologies is presented. Each topology is classified according to its mode of operation and a family tree is derived encompassing all converter types. Selected converters in each class are analysed, simulated and key operational characteristics identified. Issues associated with the practical implementation of analysed topologies are discussed in detail. Of all AC-AC conversion techniques, it is concluded that softswitching converter topologies offer the most attractive alternative to the standard hard switched converter in the power range up to 100kW because of their high performance to cost ratio. Of the softswitching converters, resonant dc-link topologies are shown to produce the poorest output performance although they offer the cheapest solution. Auxiliary pole commutated inverters, on the other hand, can achieve levels of performance approaching those of the hard switched topology while retaining the benefits of softswitching. It is concluded that the auxiliary commutated resonant pole inverter (ACPI) topology offers the greatest potential for exploitation in spite of its relatively high capital cost. Experimental results are presented for a 20kW hard switched inverter and an equivalent 20kW ACPI. In each case the converter controller is implanted using a digital signal processor. For the ACPI, a new control scheme, which eliminates the need for switch current and voltage sensors, is implemented. Results show that the ACPI produces lower overall losses when compared to its hardswitching counterpart. In addition, device voltage stress, output dv/dt and levels of high frequency output harmonics are all reduced. Finally, it is concluded that modularisation of the active devices, optimisation of semiconductor design and a reduction in the number of additional sensors through the use of novel control methods, such as those presented, will all play a part in the realisation of an economically viable system.Research Committee of the University of Newcastle upon Tyn

Design of an Advanced Programmable Current-Source Gate Driver for Dynamic Control of SiC Device

Silicon carbide (SiC) power devices outperform Silicon-based devices in operational voltage levels, power densities, operational temperatures and switching frequencies. However, the gate oxide of SiC-based device is more fragile compared with its Si counterpart. The vulnerability of the gate oxide in SiC power devices requires the development of a gate driver that is able to have more control during the turn-on and turn-off process. This paper proposes an innovative current-source gate driver where the gate current can be fully programmed. The novelty of the gate driver is that the dynamic switching transients and the static on/off-state can be controlled independently. In order to achieve this approach, a signal decomposition and reconstruction technique is proposed to apply the separate control over the dynamic switching transient and the static on/off-state gate voltage respectively. The fundamental principle of the proposed circuit is verified in simulation. In addition, a prototype of the active gate driver has been built and tested to validate the effectiveness of the flexible control over the gate voltage

Nonlinear Analysis and Control of Interleaved Boost Converter Using Real-Time Cycle to Cycle Variable Slope Compensation

Switched-mode power converters are inherently nonlinear and piecewise smooth systems that may exhibit a series of undesirable operations that can greatly reduce the converter's efficiency and lifetime. This paper presents a nonlinear analysis technique to investigate the influence of system parameters on the stability of interleaved boost converters. In this approach, Monodromy matrix that contains all the comprehensive information of converter parameters and control loop can be employed to fully reveal and understand the inherent nonlinear dynamics of interleaved boost converters, including the interaction effect of switching operation. Thereby not only the boundary conditions but also the relationship between stability margin and the parameters given can be intuitively studied by the eigenvalues of this matrix. Furthermore, by employing the knowledge gained from this analysis, a real-Time cycle to cycle variable slope compensation method is proposed to guarantee a satisfactory performance of the converter with an extended range of stable operation. Outcomes show that systems can regain stability by applying the proposed method within a few time periods of switching cycles. The numerical and analytical results validate the theoretical analysis, and experimental results verify the effectiveness of the proposed approach

Design and control of a bidirectional wireless charging system using GaN devices

Most of the existing wireless power transfer system works in unidirectional with one-direction control signals. This paper presents a bidirectional wireless charging system with duplex communication method, which is not only able to achieve the two-way wireless power transmission, but also transfer control signals bi-directionally. The power circuit operation mode is actively controlled by using the wireless transceiver module which can duplex communication to deliver measured signals remotely. The operational principle is analytically studied in details and is verified by simulation. Finally, a prototype of the bidirectional charging system using GaN devices has been successfully designed and tested. In addition, the measured feedback signals are effectively transmitted to validate the control algorithm

Polynomial Curve Slope Compensation for Peak-Current-Mode-Controlled Power Converters

Linear ramp slope compensation (LRC) and quadratic slope compensation (QSC) are commonly implemented in peak-current-mode-controlled dc-dc converters in order to minimize subharmonic and chaotic oscillations. Both compensating schemes rely on the linearized state-space averaged model (LSSA) of the converter. The LSSA ignores the impact that switching actions have on the stability of converters. In order to include switching events, the nonlinear analysis method based on the Monodromy matrix was introduced to describe a complete-cycle stability. Analyses on analog-controlled dc-dc converters applying this method show that system stability is strongly dependent on the change of the derivative of the slope at the time of switching instant. However, in a mixed-signal-controlled system, the digitalization effect contributes differently to system stability. This paper shows a full complete-cycle stability analysis using this nonlinear analysis method, which is applied to a mixed-signal-controlled converter. Through this analysis, a generalized equation is derived that reveals for the first time the real boundary stability limits for LRC and QSC. Furthermore, this generalized equation allows the design of a new compensating scheme, which is able to increase system stability. The proposed scheme is called polynomial curve slope compensation (PCSC) and it is demonstrated that PCSC increases the stable margin by 30% compared to LRC and 20% to QSC. This outcome is proved experimentally by using an interleaved dc-dc converter that is built for this work

A ripple reduction method for a two stages battery charger with multi-winding transformer using notch filter

This paper presents a two-stage battery charger consisting of a bridgeless Totem-pole power factor correction (TP-PFC) circuit and a full bridge converter with a multi-winding transformer. By using this transformer the cell equalizing operation can be achieved with no additional circuitry. In addition, a double-line frequency ripple reduction method is proposed to address the low frequency current ripples issues existing in both primary and secondary winding of the transformer which is caused by the voltage ripples across the intermediate DC link bus. Control and analysis of the converter at different operation modes is illustrated in detail and simulation results validate the effectiveness of the proposed converter and control algorithm

In situ diagnostics and prognostics of wire bonding faults in IGBT modules for electric vehicle drives

This paper presents a diagnostic and prognostic condition monitoring method for insulated-gate bipolar transistor (IGBT) power modules for use primarily in electric vehicle applications. The wire-bond-related failure, one of the most commonly observed packaging failures, is investigated by analytical and experimental methods using the on-state voltage drop as a failure indicator. A sophisticated test bench is developed to generate and apply the required current/power pulses to the device under test. The proposed method is capable of detecting small changes in the failure indicators of the IGBTs and freewheeling diodes and its effectiveness is validated experimentally. The novelty of the work lies in the accurate online testing capacity for diagnostics and prognostics of the power module with a focus on the wire bonding faults, by injecting external currents into the power unit during the idle time. Test results show that the IGBT may sustain a loss of half the bond wires before the impending fault becomes catastrophic. The measurement circuitry can be embedded in the IGBT drive circuits and the measurements can be performed in situ when the electric vehicle stops in stop-and-go, red light traffic conditions, or during routine servicing

Determination of Stray Inductance of Low-Inductive Laminated Planar Multiport Busbars Using Vector Synthesis Method

Laminated busbars connect capacitors with switching power modules, and they are designed to have low stray inductance to minimize electromagnetic interference. Attempts to accurately measure the stray inductance of these busbars have not been successful. The challenge lies with the capacitors, as they excite the busbar producing their individual stray inductances. These individual stray inductances cannot be arithmetically averaged to establish the total stray inductance that applies when all the capacitors excite the busbar at the same time. It is also not possible to measure the stray inductance by simultaneous excitation of each capacitor port using impedance analyzers. This paper presents a solution to the above dilemma. A vector synthesis method is proposed, whereby the individual stray inductance from each capacitor port is measured using an impedance analyzer. Each stray inductance is then mapped into an xyz frame with a distinct direction. This mapping exercise allows the data to be vectored. The total stray inductance is then the sum of all the vectors. The effectiveness of the proposed method is demonstrated on a busbar designed for H-bridge inverters by comparing the simulation and practical results. The absolute error of the total stray inductance between the simulation and the proposed method is 0.48 nH. The proposed method improves the accuracy by 14.9% compared to the conventional technique in measuring stray inductances

Real-time temperature estimation for power MOSFETs considering thermal ageing effects

This paper presents a novel real-time power-device temperature estimation method that monitors the power MOSFET's junction temperature shift arising from thermal aging effects and incorporates the updated electrothermal models of power modules into digital controllers. Currently, the real-time estimator is emerging as an important tool for active control of device junction temperature as well as online health monitoring for power electronic systems, but its thermal model fails to address the device's ongoing degradation. Because of a mismatch of coefficients of thermal expansion between layers of power devices, repetitive thermal cycling will cause cracks, voids, and even delamination within the device components, particularly in the solder and thermal grease layers. Consequently, the thermal resistance of power devices will increase, making it possible to use thermal resistance (and junction temperature) as key indicators for condition monitoring and control purposes. In this paper, the predicted device temperature via threshold voltage measurements is compared with the real-time estimated ones, and the difference is attributed to the aging of the device. The thermal models in digital controllers are frequently updated to correct the shift caused by thermal aging effects. Experimental results on three power MOSFETs confirm that the proposed methodologies are effective to incorporate the thermal aging effects in the power-device temperature estimator with good accuracy. The developed adaptive technologies can be applied to other power devices such as IGBTs and SiC MOSFETs, and have significant economic implications