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10th International Conference on Power Electronics-ECCE Asia

May 27 - 30, 2019 / BEXCO, Busan, Korea

An Interleaved Single-Stage Bridgeless CCM


AC-DC Converter with Wide Output Voltage
Range
Adhistira M. Naradhipa, Suhan Kang, and Sewan Choi, Fellow, IEEE
Seoul National University of Science and Technology
Seoul, Korea
E-mail: schoi@seoultech.ac.kr

Abstract—This paper proposes a new interleaved single- duty control for power factor correction (PFC) as well as
stage ac-dc converter that can achieve power factor power regulation. All of the switches can achieve ZVS
correction without input current sensing. The converter use turn-on with the help of small magnetizing inductance. But,
a bridgeless structure that can operate in CCM without the low-frequency component free in the transformer is not
reverse recovery issue. All switches achieve ZVS turn-on and guaranteed due to asymmetrical duty cycle control.
all diodes achieve ZCS turn-off, which are maintained
throughout the whole grid cycle. A SDAB-based modulation
Moreover, a large input inductance value is needed to
strategy is applied which result in simple power control, achieve the current harmonic distortion requirement.
switching ripple-free input current, open-loop PFC operation Another CCM single-stage ac-dc converter based on
and wide-range of output voltage. Experimental results from current-fed L-type half-bridge in [8]-[9] uses an
a proof of concept 2.5-kW, 220Vac, and 200Vdc – 350Vdc interleaving CCM operation. Therefore, smaller input
prototype are given to verify the working principle and inductor can be used to achieve the required harmonic
feature of the proposed converter. distortion requirement. Moreover, due to the transformer
connected to two legs with 1800 phase-shift in the
Index Terms— Single-stage AC-DC converter, wide switching period, it can be guaranteed that the transformer
voltage range, soft-switching, and switching ripple-free only consists of a pure-high frequency component.
Varying duty control is also implemented for PFC and
I. INTRODUCTION power regulation. All of the switches can achieve ZVS
A plethora of applications, such as electric vehicle (EVs) turn-on when the duty cycle is more than 0.5 but it loses
battery charger, front-end of switch mode power supply ZVS turn-on when the duty cycle is below 0.5. These
(SMPS), and telecom power supply, requires an ac-dc converters have basically a step-up conversion gain. Thus,
converter. Electrical isolation by means of using a high- most of the aforementioned single-stage ac-dc converter
frequency transformer is preferred to satisfy the safety can be considered having a narrow output voltage range.
regulation in these applications. A recent paper, published by the author in [10], proposed
In general, there are two types of high-frequency isolated a bridgeless single-stage ac-dc converter that can maintain
ac-dc converter, which are two-stage [1]-[2] and single- the soft-switching operation for whole grid-cycle with a
stage configuration. The single-stage isolated ac-dc simple one degree of freedom power control and can
converter has the advantages of single power conversion achieve a step-up and step-down conversion gain.
from ac-side to the dc-side by combining the PFC Moreover, it guarantees that the transformer is low-
converter and isolated dc-dc converter into a single frequency component free due to fixed 0.5 duty cycle of
converter [3]-[4]. Therefore, great attention has been given primary switches. However, the converter only uses one
to a single-stage approach because a higher efficiency and input inductor. Thus, a large inductance value is needed to
power density can be expected compared with the two- achieve the harmonic distortion requirement. Therefore, it
stage solution. becomes a bottleneck in achieving higher power density.
A single-stage ac-dc converter in [5] can achieve a high To overcome the issues of the previous works, this paper
power factor and soft-switching. However, it uses a large proposes a new interleaved single-stage ac-dc converter
number of semiconductor devices and operates in DCM that can achieve wide output voltage operation. The
with complicated control. Thus, result in low power converter maintains the bridgeless totem-pole structure of
density and efficiency. The converter based on dual- the work in [10] and also able to operate in CCM without
resonant-tank LCL in [6] reduces the number of the device reverse recovery issue. All switches can achieve ZVS turn-
by using a bridgeless structure with simple phase-shift on and all diodes can achieve ZCS turn-off for the whole
control. However, it is also operated in DCM which result grid cycle. An open-loop power factor correction and
in extra passive component for input filter to remove the simple power control are achieved by implementing a
switching component in the input current. Thus, the overall
DAB/SDAB-like modulation strategy [10]-[12]. Because
power density of the converter is decreasing. The converter
of a fixed 0.5 duty cycle of the primary switches and
in [6] only operates in step down conversion ratio.
A CCM single-stage ac-dc converter is proposed in [7]. 1800 phase-shift of the two primary switch legs, an input
This converter is based on a boost-half-bridge converter current with zero switching ripple is achievable
which use a diode bridge at the input side and a varying independent of the inductance value.

ⓒ2019 KIPE 517


Fig. 1. Circuit diagram of the proposed interleaved single-stage ac-dc converter.

II. PROPOSED SINGLE-STAGE INTERLEAVED AC-DC


CONVERTER AND WORKING PRINCIPLE ANALYSIS
The circuit diagram with a brief key waveform of the
proposed ac-dc converter is shown in Fig. 1. The proposed
converter is derived from a two-phase interleaved totem-
pole boost PFC converter combined with an isolated half-
bridge converter. A semi-active-rectifier is used in the
secondary as the rectifier circuit of the proposed ac-dc
converter. The proposed converter can be seen as the
interleaved extension of the converter proposed in [10] by
the author in order to increase the power.
Same with [10]-[12], simple power control based on
semi-dual-active-bridge (SDAB) modulation is
implemented to achieve open-loop PFC operation and a
wide range of output voltage. The leakage inductance of
the transformer or with additional series high-frequency
inductance, Ls, is utilized to transfer the power from ac-
side to the dc-side of the proposed converter.
In this interleaved version of the proposed ac-dc
converter, two high-frequency transformers are used. Each
primary side of the transformer is connected to each boost-
half-bridge switch leg and the center of the clamp capacitor.
In order to guarantee a balance power transfer for each
transformer, a series connection is implemented to connect
the secondary winding of each transformer. Thus, a
variation in the parasitic element in the transformer will
not affecting the power transfer balance in each of the
Fig. 2. Key operating waveforms of the proposed ac-dc converter in
transformers. grid period.
The operating key waveform of the proposed ac-dc
converter in the grid period is shown in Fig. 2. All of the -ing as implemented in the proposed ac-dc converter, the
switches in primary side, ST,1-2 and SB,1-2 are switched with input current ripple magnitude formula is given by (1). The
fixed 0.5 duty cycle with top and bottom switches have a input current is the sum of the two input inductor current.
complementary switching pattern. A 1800 phase-shift in Fig. 3 visualize the variation of input current ripple
switching period is applied between the switch leg in the magnitude according to the variation of the duty cycle.
primary side of the proposed converter. This switching According to (1) and Fig. 3, the theoretical input current
method is a well-known interleaving technique which is switching ripple of the proposed ac-dc converter is zero.
widely used in dc-dc converter. For a two-phase interleav- Therefore, by extending the converter in [10] into a two-

518
Fig. 3. Current ripple magnitude variation with duty cycle in the two-
phase interleaving structure.

phase interleaving structure, not only the power can be


increased but also switching ripple-free input current is
achieved. With this additional feature, the input inductor,
Lg1 and Lg2, can be designed freely with any value and still
the input current achieves zero switching-ripple. Therefore,
the input inductor design is independent of the requirement
of total harmonic distortion. Only parameters such as core
loss and primary side conduction loss will be the
constraints of the input inductance value. Thus, the
proposed interleaved ac-dc converter have more flexibility
in designing input inductor compared to the previous
works.

 Vg 1 - 2D
L  f   D , D  0.5
 g s 1- D
I g   (1)
 Vg 
2 - 2D
D
1
, D  0.5
 Lg  f s 1- D 2

Other than input current switching ripple-free, a fixed 0.5 Fig. 4. Key operating waveforms of the proposed ac-dc converter in
duty cycle gives an equal voltage for the top and bottom switching period.
clamp capacitor, vC1(t) = vC2(t) = |vg(t)|, which result in no
abrupt change of clamp capacitor voltage at zero crossing. with the magnitude of Vo on the secondary side of the
The voltage applied to the transformer is vC1(t) when ST,i is transformer. The pulse-width of this three-level voltage is
on and -vC2(t) when SB,i is on. Because of fixed the 0.5 duty following the shape of (2) as shown in Fig. 2.
cycle, the period for each vC1(t) and -vC2(t) applied to the
transformer is equal to 0.5Ts. Therefore, the transformer is d (t )  m f  sin  2 f g t  (2)
guaranteed to have only high-frequency component
despite having a voltage envelope with |sin(2πfgt)| function There are two variables that can be used to regulate the
as shown in Fig. 2 and 4. DC output power or voltage, which are modulation index,
The semi-active-rectifier (SAR) in the secondary side mf, and the phase shift, φ, between primary and secondary
has two switches, S3 and S4, and two output diodes, D3 and carrier signals as shown in Fig.2. For simplicity, only
D4. These two switches are 1800 phase-shift switched with output power regulation by phase shift control is
a duty cycle of d(t) as defined in (2). The duty cycle of the considered in this paper and modulation index is selected
switches in SAR is shaped with |sin(2πfgt)| waveform with to be 0.5. The effect of modulation index control will be
the peak value of modulation index, mf, in order to achieve addressed in future work.
open-loop PFC operation [10]. Unlike some of the The control structure of the proposed ac-dc converter is
previous works which need a direct shaping of input shown in Fig. 5. The voltage or power regulation is done
current, by means of input current sensing, to achieve using a simple PI control which produces a phase shift
CCM unity power factor, the proposed ac-dc converter can between the primary and secondary carrier signal. A fixed
remove the input current sensor and still achieving CCM 0.5 duty cycle is compared with the primary carrier signal
unity power factor. Therefore, a simple control structure and gives the turn-on or off command to the primary
can be used in the proposed ac-dc converter. The switching switches.
action in SAR produces a three-level square wave voltage

519
n  vg (t ) Vo 2 (t )  m(t )  (t )
poI (t ) Ts
       (t )  (6)
4 f s Ls
2
2
n v g (t ) Vo  m 2  (t )       (t )   m   (t )   (t )  2 (t )  (t )  
poII (t )    (7)
Ts
4 f s Ls  m (t )  2      (t )  2 (t )  (t )   2 
2


2 (t )  1  m(t )   
 (t )  (4)
m (t )  2

Vo
m (t )  (5)
n vg (t )

From (2)-(5), it can be seen that these variables are


moving with grid frequency, although it needs to be noted
that these variables are constant in switching period.
Therefore, the value of average power transfer in switching
period will move according to the grid period and it is
defined as an instantaneous power transfer, <po>Ts.
According to the value of α(t), the proposed ac-dc
converter has two different operating modes in the
switching period. The boundary between mode I and mode
II is when α(t) equal to 1800. Using (2)-(5) the
Fig. 5. Control structure of the proposed ac-dc converter. instantaneous average output current, <io>Ts, for each
mode can be derived by analyzing the iLs current which
A PLL is used to extract the grid voltage angle and flows into D3 and D4 as shown in Fig. 4. The power transfer
produce an absolute sinusoidal waveform. The sinusoidal in each mode is derived by multiplying <io>Ts in each
waveform is multiplied by modulation index and produce mode by the output voltage Vo. The instantaneous power
a duty signal, (2), for the switches in SAR. transfer, <po,i>Ts, formula is given by (6) and (7) at the top
In the switching period, the converter working principle of this page.
is similar to a semi-dual-active-bridge converter. The Unlike the DAB-based ac-dc converter in [12] that
leakage inductance or series inductance current is shaped change the operation mode according to the given value of
by the primary and secondary voltage. The amount of φ, the proposed ac-dc converter change the operation mode
instantaneous average output current, <io>Ts, is based on α(t) and it automatically changes during half grid
determined by the phase angle between the positive pulse period. It needs to be noted that (6) is equal with (7) when
of nvab and the positive pulse of vcd, and the non-power α(t) is equal to 1800. Thus, there is no power jump at the
transfer period, vcd = 0V, as shown in Fig. 4. Like SDAB mode change boundary that may cause a transient issue in
converter, all of the switches can achieve ZVS turn-on and the proposed ac-dc converter.
all of the diode can achieve ZCS turn-on. With correct
design, the soft-switching performance can be maintained III. EXPERIMENTAL RESULTS
for a whole grid cycle. A 2.5kW, 220Vac, and 200Vdc – 350Vdc is built to verify
The power transfer formula in the switching period can the operating principle and features of the proposed ac-dc
be derived in the same fashion with the SDAB converter converter. Fig. 6(a) and (b) shows the basic operation
in [14]. Unlike dual-active-bridge (DAB) converter where principle at different output voltage condition. As shown
the given phase-shift, φ, between primary and secondary in Fig. 6(a) and (b), the experimental key waveform at grid
carrier is directly translated into the phase-shift, α(t), period coincides with the theoretical key waveform as
between nvab and vcd. The SDAB α(t) is determined by the shown in Fig. 2. Some discontinuity in the grid current can
formula given in (3). The period when vcd = 0V or non- be observed around zero-crossing of the grid voltage. This
power transfer period, β(t), also need to be defined in order discontinuity is caused by the SAR switches are not
to derive the power transfer formula. By using the switching due to a low value of d(t) and the value of gate
derivation in [14], β(t) is given by (4) with m(t) is the ratio
resistance is not small enough. It can be easily removed by
between the output voltage and input voltage as defined by using smaller gate resistance or implement a lower limit
(5). value of d(t). Measured with Yokogawa WT3000, the
power factor is maintained more than 0.99 and the THD is
 (t )  1.5  d (t )      (3) below 5%.
Fig. 6(a) and (b) also shows an experimental proof of
concept that the proposed converter can operate well under

520
(a) (a)

(b)
(b)
Fig. 6. Grid operation key waveforms at different output voltage: (a) Vo
= 200V, (b) Vo = 350V.

(c)

Fig. 7. Experimental waveforms of switching ripple-free input current.

a wide range of output voltage. In Fig. 6(a) the proposed


ac-dc converter work in buck mode converting 220Vac into
200Vdc and in boost mode converting 220Vac into 350Vdc
as shown in Fig. 6(b). Thus, the proposed ac-dc converter
is suitable for wide output voltage range applications such
as EV charger.
The proof of concept that the converter can operate with
zero input current ripple is shown in Fig. 7. The proposed
ac-dc converter use Lg1 ≈ Lg2 = 323uH. As shown in Fig. 7
both ILg1 and ILg2 have a large switching ripple. However, (d)
the input grid current have near zero switching ripple.
Fig. 8. Switching period experimental waveforms: (a) SDAB operation,
Some ripple in the input grid current exists due to a (b) primary switch ZVS turn-on, (c) secondary switch ZVS turn-on, (d)
difference in the value of Lg1 and Lg2. Compared with the secondary diode ZCS turn-off.
previous works in [10] with input inductor of 1mH, the
input inductance value of the proposed ac-dc converter is The ZVS turn-on for switches is achieved as well as the
much smaller to achieve the same %THD performance. ZCS turn-off of diodes. All the experimental waveform
The proof of concept operation at switching period is from the proof of concept prototype coincides with the
shown in Fig. 8(a)-(d). As shown in Fig. 8(a) the iLs is theoretical waveform.
shaped by vab and vcd. The soft switching performance is
shown in Fig. 8(b)-(d).

521
IV. CONCLUSION switching AC-DC converter," 2018 IEEE Applied Power
Electronics Conference and Exposition (APEC), San
A new interleaved bridgeless high-frequency isolated Antonio, TX, 2018, pp. 3405-3410.
single-stage ac-dc converter is proposed. The converter is [10] Adhistira M.N., S. Kang, B. Kim, S. Choi, "A New Single-
able to achieve a CCM PFC operation without input Stage Bridgeless Boost Half-Bridge AC/DC Converter with
current sensing. Moreover, the proposed ac-dc converter Semi-Active-Rectifier," 2019 IEEE Applied Power
achieve input current with zero switching ripple due to Electronics Conference and Exposition (APEC), Anaheim,
two-phase interleaving structure and fixed primary 0.5 CA, 2019.
duty cycle. Moreover, a 0.5 fixed duty cycle in primary [11] N. D. Weise, G. Castelino, K. Basu and N. Mohan, "A
guarantee only pure high-frequency component exists in Single-Stage Dual-Active-Bridge-Based Soft Switched
AC–DC Converter With Open-Loop Power Factor
the transformer and soft-switching for all semiconductor
Correction and Other Advanced Features," in IEEE
devices is achieved without the need of reducing the Transactions on Power Electronics, vol. 29, no. 8,pp.4007-
magnetizing inductance value. Therefore, a small-sized 4016,Aug.2014.
isolation transformer without gap can be used in the [12] R. Baranwal, K. V. Iyer, K. Basu, G. F. Castelino and N.
proposed converter. A proof of concept experimental Mohan, "A Reduced Switch Count Single-Stage Three-
prototype of a 2.5kW under 220Vac and 200Vdc -350Vdc Phase Bidirectional Rectifier With High-Frequency
is built to verify the theoretical working principle. Isolation," in IEEE Transactions on Power Electronics, vol.
33, no. 11, pp. 9520-9541, Nov. 2018.
ACKNOWLEDGMENT [13] H. Belkamel, H. Kim, B. Kim, Y. Shin and S. Choi, "Bi-
Directional Single-Stage Interleaved Totem-Pole AC-DC
This work was supported by the National Research Converter with High Frequency Isolation for On-Board EV
Foundation of Korea (NRF) grant funded by the Korea Charger," 2018 IEEE Energy Conversion Congress and
Government (MSIT) (2017R1A2A2A05001054). Exposition (ECCE), Portland, OR, 2018, pp. 6721-6724.
[14] S. Kulasekaran and R. Ayyanar, "Analysis, Design, and
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