Design of Bidirectional DC - DC Resonant Converter For Vehicle-to-Grid (V2G) Applications

This article has been accepted for publication in a future issue of this journal, but has not been
fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TTE.2015.2476035, IEEE Transactions on Transportation Electrification
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Design of Bidirectional DC- DC Resonant

Converter for Vehicle-to-Grid (V2G) Applications
Zaka Ullah Zahid, Student Member, IEEE, Zakariya M. Dalala, Member, IEEE, Rui Chen, Student
Member, IEEE, Baifeng Chen, Student Member, IEEE, and Jih-Sheng (Jason) Lai, Fellow, IEEE
 literature [4-15]. The main focus in these converters is on

Abstract— In this paper, a detailed design procedure is presented achieving soft-switching in the power switches for a wide range
for a bidirectional CLLLC-type resonant converter for a battery of load variation to get rid of the EMI, and to enable very high-
charging application. This converter is similar to an LLC-type frequency operation so that the size, and thus the cost, of the
resonant converter with an extra inductor and capacitor in the
magnetics and the output filter is minimized. Both non-isolated
secondary side. Soft-switching can be ensured in all switches without
additional snubber or clamp circuitry. Because of soft-switching in [4-7] and isolated [8-15] converters are proposed. The
all switches, very high-frequency operation is possible, thus the size advantages with the non-isolated converters are fewer numbers
of the magnetics and the filter capacitors can be made small. To of components and high power-stage efficiency. However, in
reduce the size and cost of the converter, a CLLC-type resonant some applications, including EV battery chargers, galvanic
network is derived from the original CLLLC-type resonant network. isolation is required for safety between the primary-side and the
First in this paper, an equivalent model for the bidirectional
secondary side [10].
converter is derived for the steady-state analysis. Then, the design
methodology is presented for the CLLLC-type resonant converter. In the PWM converters, the phase-shifted full-bridge (PSFB)
Design of this converter includes determining the transformer turns converter is the most widely used topology for a wide input and
ratio, design of the magnetizing inductance based on ZVS condition, a wide output voltage range conditions [16, 17]. However, this
design of the resonant inductances and capacitances. Then, the topology suffers from a number of issues for a wide range of
CLLC-type resonant network is derived from the CLLLC-type load variation. The ZVS range depends on the primary-side
resonant network. To validate the design procedure, a 3.5 kW
transformer leakage inductance. To achieve ZVS for all load
converter was designed following the guidelines in the proposed
methodology. A prototype was built and tested in the lab. and line conditions, large leakage inductance is required [18,
Experimental results verified the design procedure presented. 19]. This, however, results in duty cycle loss and it increases
the reactive energy in the circuit for certain load conditions,
Index Terms— dc-dc power converters, Design methodology, which decreases converter efficiency [20]. Because of the
Resonant converters, Bidirectional power flow, Battery charger. energy stored in the transformer secondary-side leakage
inductance, there is severe parasitic ringing in the secondary
I. INTRODUCTION side switches. To damp or clamp this ringing, RCD snubbers,
R ECENTLY, electric vehicles (EVs) and plug-in hybrid

electric vehicles (PHEVs) have gained popularity because
of their advantages, such as more environmentally friendly, less
lossless snubbers or active clamp circuits are used [21]. These
extra circuitries allow the reduction of the voltage spikes across
the secondary switches. However, they increase the size, cost
noisy and more efficient [1]. Power converters powered from and circuit complexity. Even with these snubber or clamp
utility charge the batteries in these vehicles. In vehicle-to-grid circuits, the voltage stress on the secondary side switches is
(V2G) applications, these battery chargers are bidirectional, higher than the output voltage, making this topology unsuitable
capable of transferring power back to the grid. Vehicles with for high output voltage applications [21].
V2G capability can serve as a distributed energy resource Resonant converters are becoming a desirable topology for
providing power to the utility loads, regulate the voltage and high-power dc-dc applications [22-30]. In some applications;
frequency and help the utility load leveling [2]. These vehicles resonant converters are the natural choice as the reactive effects
can absorb excessive energy produced by the renewable energy are noticeable and unavoidable [22-25] while in other
sources like wind and photovoltaic [3, 4]. applications [26-29], these converters are used because they
Vehicles with V2G capability require a bidirectional battery offer a number of advantages over the non-resonant type
charger that consists of a bidirectional ac-dc converter followed topologies, including soft-switching in all switches, very high-
by a bidirectional dc-dc converter. The dc-dc converters frequency operation, low EMI, simple control, high efficiency
manage the power flow between the dc bus and the battery. A and fewer component counts. It eliminates the need of clamp or
number of bidirectional dc-dc converters can be found in the snubber circuitry. One of the most popular resonant topology
This paragraph of the first footnote will contain the date on which you State University, Blacksburg, VA, USA. (email: [email protected],
submitted your paper for review. [email protected], [email protected], [email protected]).
Zaka Ullah Zahid, Rui Chen, Baifeng Chen and Jih-Sheng (Jason) Lai are Zakariya M. Dalala is with the Department of Energy Engineering, German
with Future Energy Electronics Center at Virginia Polytechnic Institute and Jordanian University, P.O. Box 35247 Amman 11180 Jordan (email:
[email protected]).
2332-7782 (c) 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See
http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
for a wide input and wide output voltage range is the LLC is transferred from the battery to the dc bus. This converter has
converter [11, 30]. However, this topology is suitable for a a symmetric structure in both directions. This converter is
unidirectional power transfer. In the regeneration mode, the similar to an LLC resonant converter with extra inductor and
magnetizing inductance is in parallel with the bridge voltage, capacitor in the secondary side. Switches in the primary-side
and it is no longer part of resonant network, converting the form a high-frequency full-bridge inverter converting the input
topology into a series resonant converter (SRC). The efficiency dc voltage into a quasi-square wave ac while the switches in the
of SRC drops considerably as the operating switching secondary-side serve as a rectifier converting the high-
frequency drifts away from the series resonant frequency, frequency ac into a dc output voltage. The inverting and
making it unsuitable for a very wide input and output voltage rectifying switches are separated by the resonant network
range applications. consisting of resonant inductances (L1 and L2), transformer
A symmetric unity gain bidirectional LLC converter was magnetizing inductance (Lm) and the two resonant capacitors
proposed in [29]. This topology has all the advantages of that (C1 and C2). The transformer provides the galvanic isolation
LLC converter, and is capable of transferring power in either between the primary-side and the secondary side. The
direction. However, the converter in [29] was designed for a magnetizing inductance and the leakage inductances of the
unity gain condition only, for which the resonant network transformer are part of the power stage. The resonant capacitors
components are symmetrical on both sides. At unity gain, the are not only part of the resonant network but they also block
converter operates at the primary-side series resonant any dc voltage offset in the generated quasi-square voltage
frequency, and the voltage gain curves are always generated by the inverting bridge.
monotonically decreasing. In the battery charging applications,
B. The Steady-State Model
the battery voltage varies significantly during the whole
charging process, and the bidirectional converter experiences a Without a thorough theoretical analysis of the resonant
very wide input and a very wide output voltage range. And, converter, it is quite difficult to achieve good designs of the
since the voltage gain of the converter is not unity at all converter. The steady-state model for the converter operating in
operating points, the resonant network is no longer the BCM is derived here. The model for the converter operating
symmetrical. And, multiple peaks can appear in the voltage gain in the RM can be derived in a similar fashion. The equivalent
curves under certain load and line conditions. Hence for a model of the resonant converter operating in the BCM is shown
battery charging applications, the design methodology in Fig. 2.
Io
proposed in [29] is not enough. A new design methodology is
QA QC QE QG
needed that takes in to account the wide input and wide output i1 i2
C1 C2
voltage range, and which can ensure that the voltage gain curves VDC CDC
+ L1 L2 + Cf VBatt
vAB Lm n 1 vCD
are always monotonically decreasing for all load and line - -
conditions. QB QD QF QH
The main objectives of this paper are; to propose a simple
design methodology of the power stage for a bidirectional
battery charging applications for a wide input and a wide output Fig. 1. Circuit topology for bidirectional resonant converter.
voltage range, and to derive the CLLC-type network from the i1 i2
v1 - iprim v2 -
+
CLLLC-type network to reduce the size and the cost of the + Io +

C1 L1 L2 C2 vCf
converter. In Section II, an equivalent model for the converter + + - Cf
vAB Lm n 1 vCD Irect RL Vo
im
operating in the battery charging mode is developed for the - - iCf Rc -

steady-state analysis. In Section III, a detailed design
methodology for a CLLLC-type converter is presented, and a Fig. 2. Equivalent circuit for resonant converter operating in the BCM.
CLLC network is derived from it. As a design example, a 3.5 Given an input voltage VDC and a desired output voltage Vo,
kW converter is designed following the proposed designed the voltages across the two bridges can be expressed in (1) and
methodology in Section IV for a voltage gain requirement that (2). The secondary equivalent circuit can be represented by a
is a buck-boost in either direction. Section V provides the rectified current irect, expressed in (3), supplying to the output
experimental results for the converter operating in the battery filter and load. Since, the resonant network is tuned to the
charging mode and in the regeneration mode validating the fundamental frequency, the energy is transferred by the
design methodology and the derivation of CLLC network. fundamental component of the frequency only. And, the quasi-
Finally, a summary of the discussions is presented. square voltage, vAB, can be represented by its fundamental
sinusoidal component.
II. FUNDAMENTAL ANALYSIS
4 𝑉𝐷𝐶
𝑣𝐴𝐵 = ∙ sin(𝜔𝑠 𝑡) (1)
A. Converter Power Stage 𝜋
Fig. 1 shows the circuit topology for the resonant converter
capable of transferring power in both directions. In the battery 𝑣𝐶𝐷 = 𝑠𝑖𝑔𝑛(𝑖2 ) ∙ 𝑉𝑜 (2)
charging mode (BCM), the power is transferred from the dc bus
to the battery, while in the regeneration mode (RM), the power
𝑖𝑟𝑒𝑐𝑡 = |𝑖2 | (3) 2

𝑉𝑜 = 𝑉𝐶𝑓 = 𝐼 𝑅 (10)
𝜋 𝑝𝑘 𝐿
This equivalent model is similar to the equivalent model for 𝑉𝑜 2
a Series-Series compensated Induction Power Transfer (IPT) 𝐼𝑜 = = 𝐼 (11)
𝑅𝐿 𝜋 𝑝𝑘
system [22]. The steady-state model and the small-signal model
derived in [22] are valid for this converter as well. The only Where,
difference is, for the IPT system, the turns ratio is equal to 1 but
𝐼𝑝𝑘 2 = (𝐼2𝑠 )2 + (𝐼2𝑐 )2
here it is equal to the actual transformer turns ratio.
For the steady-state analysis, the currents and voltages in the The converter output voltage versus the operating switching
circuit in Fig. 2 can be approximated to be pure sinusoidal, and frequency curve and the output current versus the operating
can be written as the sum of sine terms and cosine terms. These switching frequency curve can be plotted using (10) and (11).
currents and voltages are, With the phase-shift control, the ZVS range depends on the
series leakage inductance. In this topology, the series
𝑖1 = 𝐼1𝑠 ∙ sin(𝜔𝑠 𝑡) + 𝐼1𝑐 ∙ cos(𝜔𝑠 𝑡) (4) inductance is part of the resonant network, and thus with phase-
𝑣1 = 𝑉1𝑠 ∙ sin(𝜔𝑠 𝑡) + 𝑉1𝑐 ∙ cos(𝜔𝑠 𝑡) (5) shift control, the ZVS cannot be ensured at all load and line
𝑖2 = 𝐼2𝑠 ∙ sin(𝜔𝑠 𝑡) + 𝐼2𝑐 ∙ cos(𝜔𝑠 𝑡) (6) conditions. To overcome this problem, a variable frequency
𝑣2 = 𝑉2𝑠 ∙ sin(𝜔𝑠 𝑡) + 𝑉2𝑐 ∙ cos(𝜔𝑠 𝑡) (7) approach is adapted here. With this approach, ZVS can be
The steady-state equations derived in [22] in matrix form are: maintained at all load and line conditions as long as the
𝐵𝑠𝑡 = 𝐴𝑠𝑡 ∙ 𝑋𝑠𝑡 (8) primary-side current lags behind the primary-side bridge
where, voltage in the operating switching frequency range.
𝐿𝑒𝑞2 𝐿𝑒𝑞2 𝑅𝑒
1 0 0 0 −Ω𝑠 𝐿𝑒𝑞2 0
𝐿𝑒𝑞𝑚 𝐿𝑒𝑞𝑚 C. Steady-State Operation of the Converter
𝐿𝑒𝑞𝑚 𝐿𝑒𝑞𝑚 𝑅𝑒
1 0 0 0 0 −Ω𝑠 𝐿𝑒𝑞𝑚 The output voltage versus the operating switching frequency
𝐿𝑒𝑞1 𝐿𝑒𝑞1
0 0 1 0 Ω𝑠 𝐶1 0 0 0
curves and the output current versus the operating switching
0 0 0 1 0 Ω𝑠 𝐶2 0 0 frequency curves for the bidirectional converter can be plotted
𝐴𝑠𝑡 =
𝐿𝑒𝑞2 𝐿𝑒𝑞2 𝑅𝑒 using (10) and (11). Fig. 3 shows the voltage gain curves for the
0 0 Ω𝑠 𝐿𝑒𝑞2 0 1 0
𝐿𝑒𝑞𝑚 𝐿𝑒𝑞𝑚
converter under different load conditions with the transformer
𝐿𝑒𝑞𝑚 𝐿𝑒𝑞𝑚 𝑅𝑒
0 0 0 Ω𝑠 𝐿𝑒𝑞𝑚 1 0 turns ratio equal to 1.
𝐿𝑒𝑞1 𝐿𝑒𝑞1
−Ω𝑠 𝐶1 0 0 0 0 0 1 0
[ 0 −Ω𝑠 𝐶2 0 0 0 0 0 1 ]
The gain of the converter is unity at the primary-side series
resonant frequency, fser. The gain of the converter is more than
unity for frequencies lower than fser, and the gain is less than
𝐵𝑠𝑡 = [𝑉𝑒 𝑉𝑒 0 0 0 0 0 0]𝑇
unity for frequencies greater than fser. These gain curves can be
divided into three regions, namely, Region 1, 2 and 3.
𝑋𝑠𝑡 = [𝑉1𝑠 𝑉2𝑠 𝐼1𝑠 𝐼2𝑠 𝑉1𝑐 𝑉2𝑐 𝐼1𝑐 𝐼2𝑐 ]𝑇
and, Large RL
4
∙ 𝑉𝑔 𝑉𝑒 =
𝜋 Series Resonant
8
𝑅𝑒 = 2 𝑅𝐿 Region 2 Frequency
𝜋
Ω𝑠 = 2 ∙ 𝜋 ∙ 𝑓𝑠𝑤
𝑛2 𝐿11 𝐿22 − 𝐿𝑚 2 Small RL
𝐿𝑒𝑞1 =
𝑛2 𝐿11
𝑛 𝐿11 𝐿22 − 𝐿𝑚 2
2
𝐿𝑒𝑞2 =
𝑛2 𝐿22
𝑛 𝐿11 𝐿22 − 𝐿𝑚 2
2
𝐿𝑒𝑞𝑚 = Region 3 Region 1
𝑛 𝐿𝑚
The sine and cosine components in (4) – (7) can be
calculated by solving the system of linear equations in (8),
𝑋𝑠𝑡 = 𝐴𝑠𝑡 −1 ∙ 𝐵𝑠𝑡 (9) Fig. 3. The voltage gain versus the operating switching frequency curves
under different load conditions.
These sine and cosine components can be plugged back into
the equations (4)-(7) to get all the currents and voltages in the a) Region 1
circuit in Fig. 2. The output current and the output voltage at This region consists of the frequencies higher than the fser.
steady-state can be calculated using the following equations, In this region, the primary-side switches turn on at zero voltage
condition, whereas the secondary side switches turn on and turn
off at zero currents. The gain of the converter in this region is III. DESIGN OF THE BIDIRECTIONAL CONVERTER
always less than unity under any output load conditions. The The resonant network in the CLLLC-type converter has
voltages and the currents for converter operating in this region five elements (L1, L2, Lm, C1 and C2). There is a transformer for
are shown in Fig. 4. Fig. 5 shows the voltages and the currents galvanic isolation. Lm is the magnetizing inductance of this
for converter operating at the fser. transformer. The elements in the secondary side can be referred
VAB I_L1 I_Lm
400
Vin to the primary-side as shown in Fig. 7. If the transformer turns
200
ratio in the original circuit is 𝑛𝐶𝐿𝐿𝐿𝐶 . Then,
𝐿′2 = 𝑛𝐶𝐿𝐿𝐿𝐶 2 ∙ 𝐿2
00
-200
(12)
-Vin
-400
VCD I_L2 1
V
200o 𝐶2′ = ∙ 𝐶2 (13)
100 𝑛𝐶𝐿𝐿𝐿𝐶 2
00
8
-100
-V ′
𝑅𝑎𝑐 = 𝑛𝐶𝐿𝐿𝐿𝐶 2 ∙ 𝑅
-200o
(14)
𝜋2 𝐿
0.00598 0.005985 0.00599 0.005995 0.006
Fig. 4. The voltages and the currents for
Timethe
(s) converter operating in Region 1.
VAB I_L1 I_Lm
Vin
200
00
v1 - i1 i’2 v’2 -
+
-200
-Vin
C1 L1 L’2 C’2
400
VCD I_L2
+ +
Vo vAB Lm R’ac v’CD
im
200
00 - -
-200
-Vo
-400
Fig. 5. The
0.0054
voltages and the currents
0.00541
Timefor
(s) the converter operating at the
0.00542 0.00543 0.00544
primary-side series resonant frequency. Fig. 7. Equivalent circuit after referring elements from the secondary side to
the primary-side.
b) Region 2
A. Design of the CLLLC-type Resonant Network
This region consists of the gain curves with a negative
slope, and the operating frequencies lower than the fser. In this There are few points that need to be considered while
region, the primary-side switches turn on at zero voltage designing this converter.
condition whereas the secondary-side switches turn on and turn i) The operating frequency should be very high to reduce
off at zero currents. The secondary-side current is in the size of the magnetics and the output filter capacitor. The
discontinuous conduction mode. The gain of the converter in voltage across the resonant capacitor is inversely proportional
this region is always equal to or more than unity. The voltages to the operating switching frequency. Higher switching
and the currents for converter operating in this region are shown frequency is desirable for a lower capacitor voltage stress. So,
in Fig. 6. the converter should be designed such that the normal operating
400
VAB I_L1 I_Lm switching frequency range is high.
Vin
200
ii) The converter should be designed to have ZVS in the
primary-side switches and soft commutation in the secondary
0
0
-200
side switches to maximize the efficiency, and to make very
-Vin
-400
high-frequency operation possible.
VCD I_L2
Vo
400
iii) To minimize the circulating reactive energy in the
200 resonant tank, the phase angle, 𝜑, between the input square
00
-200
voltage and the input current should be small.
-V
-400o
Fig.0.00594 0.00595
6. The voltages 0.00596
and the 0.00597
currents for 0.00598 0.00599 0.006 iv) The designed converter should meet the voltage gain
Timethe
(s) converter operating in Region 2.
requirements in both directions of energy flow.
c) Region 3
This region consists of operating frequencies lower than the v) The gain curves should be monotonically decreasing to
fser. In this region, the gain of the converter can be more than 1 enable linear control over the entire operating frequency range
or less than 1. This is the ZCS region, where the primary-side for both modes of operation where by then, linear control
switches loses ZVS, and they turn off at zero currents. The techniques can be adapted easily.
converter is not operated in this region because the MOSFETs Design of the CLLLC-type resonant converter involves
in the primary-side suffers from severe body-diode reverse determining the transformer turns ratio (nCLLLC), design of the
recovery current resulting in significant switching losses, so magnetizing inductance (Lm), design of the resonant
MOSFETs can no longer be used in this converter. And, the inductances (L1 and L’2) and resonant capacitances (C1 and C’2).
operating switching frequency is very low in this region. So, the Once L’2 and C’2 are designed, L2 and C2 can be calculated
size of the magnetics is expected to be larger in this region. using equations (12) and (13).
a) Design of the Transformer Turns Ratio (nCLLLC) d) Design of the Resonant Capacitances (C1 and
In resonant converters, the efficiency of the power stage is C’2)
maximum at the primary-side series resonant frequency, fser. The efficiency of the converter is maximum at the primary-
Thus, the converter should operate at this frequency under side series resonant frequency, fser. Converter is operated at this
nominal operating conditions. If the primary switches and the frequency under nominal operating conditions. The choice of
secondary diodes are assumed to be ideal, then the transformer this frequency determines the operating frequency range of the
turns ratio can be calculated as, converter. So, C1 is designed based on the operating frequency
𝑁1 𝑉𝑖𝑛 range in the BCM. For a series resonant frequency of fres,
𝑛𝐶𝐿𝐿𝐿𝐶 = = (15) 1
𝑁2 𝑉𝑜_𝑛𝑜𝑚 𝐶1 = (18)
𝐿1 (2𝜋𝑓𝑟𝑒𝑠 )2
b) Design of the Magnetizing Inductance (Lm) The capacitance ratio, Cn, is defined as,
ZVS can be ensured in the primary-side switches by keeping 𝐶′2
𝐶𝑛 = (19)
the current through these switches negative on the instant they 𝐶1
are turned on. The primary current should be able to charge and Cn can be designed such that the voltage gain curves are
discharge the output capacitors of the primary-side switches monotonically decreasing, and they meet the voltage gain
during the dead-time. The magnitude of this current depends on requirements in both BCM and RM. C’2 determines the
the magnetizing inductance and the duration of the dead-time. secondary side series resonant frequency, and the converter will
So, the ZVS in the primary-side depends on the magnetizing operate at this frequency under nominal conditions in the RM.
inductance, the switch output capacitance, the operating In other words, C’2 determines the operating switching
switching frequency and the dead-time duration. The operation frequency of the converter in the RM. So, Cn cannot be too
of this converter during the dead-time is similar to the operation large, as this will make the converter operate at lower switching
of LLC resonant converter during the dead-time. So, the frequencies in the RM.
magnetizing inductance can be designed using the same Start Design
expression as the full-bridge LLC resonant converter [30]. This Process
Cal range of RL · Find range of RL at max
relationship is, (BCM & RM) output power conditions
𝑇. 𝑡𝑑𝑒𝑎𝑑
𝐿𝑚 ≤ (16)
16𝐶𝑜𝑠𝑠 Design · (Based on nominal
Having a very small magnetizing inductance will ensure nCLLLC operating conditions)
ZVS in the primary-side switches at all load and line conditions.
· (Based on ZVS
However, Lm cannot be too low. As, it would make the Design Lm
requirements)
magnetizing current very high, resulting in huge conduction
losses, increased apparent power requirements for switches and Design nL · (Based on voltage gain
increased peak voltage requirement for the primary-side requirements in both modes)
capacitor. Large magnetizing inductance will result in a small Design C1 · (Based on fser and
magnetizing current, but it limits the voltage gain of the operating frequency range)
converter. So, magnetizing inductance cannot be too large. Design C2
·
(Based on voltage gain
The dead-time between the switches also affect the ZVS End Design slopes and operating
range. Longer dead-time will help in achieving ZVS for wide Process frequency range)
Fig. 8. Design flowchart for the proposed design methodology.
input and output voltage range. And, with large dead-time, the
magnetizing inductance can be made large to reduce the
magnetizing current. However, longer dead-time will result in B. Deriving a CLLC from the CLLLC Network
large primary RMS current as no energy is transferred during In the CLLLC-type resonant network, there are three
dead-time. All these factors should be kept in mind while magnetic units (L1, L2 and Lm) and two capacitors (C1 and C2).
designing the magnetizing inductance. To reduce the number of magnetics in the resonant network, a
c) Design of Leakage Inductances (L1 and L’2) CLLC-type network, with only two magnetic units, can be
To simplify the design process, it will be assumed that L’2 derived from the CLLLC-type network. The T-network
is equal to L1. The inductance ratio, Ln, is defined as, consisting of three inductances L1, L2 and Lm in the CLLLC-type
𝐿𝑚 resonant network is shown in Fig. 7. The equivalent circuit
𝐿𝑛 = (17) consisting of an inductor, Lr and a transformer with magnetizing
𝐿1
The voltage gain and the operating switching frequency inductance M is shown in Fig. 9(b).
range of this converter depend on the inductance ratio, Ln. For L1 L’2
a narrow operating frequency range, Ln should be small.
However, small Ln will result in large leakage inductances, thus +
the size of magnetics can be large. For a large Ln, the gain of the +
vA iA Lm iB vB
converter is limited, and the operating frequency range is wide.
Fig. 11 and Fig. 12 show the voltage gain curves under the same - -
load conditions for different values of Ln.
(a) L1, L2 and Lm in a CLLLC-type resonant network.
Lr kHz, a dead-time of 200 nSec and a switch output capacitance

of 250 pF, the magnetizing inductance comes out to be,
+ + 1 −9
vA M 1 nCLLC iB vB ( 3 ) × (200 × 10 )
𝐿𝑚 ≤ 100 × 10
iA
- = 500 𝜇𝐻
- 16 × 250 × 10−12
(b) Lr, M and nCLLC in a CLLC-type resonant network A magnetizing inductance of 500 µH or less will ensure
The following equations show the terminal voltages in term ZVS in the primary-side switches. Fig. 11 shows the voltage
of the loop currents for the T-network shown in Fig. 9(a). gain curves for Lm equals to 300 µH and 200 µH. It can be seen
𝑑 𝑑 that for larger Lm, the gain of the converter is limited, and there
𝑣𝐴 = (𝐿1 + 𝐿𝑚 ) 𝑖𝐴 + 𝐿𝑚 𝑖𝐵 (20)
𝑑𝑡 𝑑𝑡 is bifurcation (multiple peaks) in the curves. The maximum
voltage gain requirement for the converter is 1.6 in the RM,
𝑑 𝑑 when the dc bus voltage is 400 V and battery voltage is 250 V.
𝑣𝐵 = 𝐿𝑚 𝑖 + (𝐿′2 + 𝐿𝑚 ) 𝑖𝐵 (21)
𝑑𝑡 𝐴 𝑑𝑡 This voltage gain can be achieved for an Lm of 200 µH or less.
The next step is to design the resonant inductances, L1 and
The terminal voltages for the equivalent circuit in Fig. 9(b) L’2. To design the inductance ratio, the voltage gain curves are
in terms of their loop currents are, plotted for different values of Ln in Fig. 11 and Fig. 12. For a
𝑑 𝑑 value of Lm equals to 200 µH and Ln equals to 10, the converter
𝑣𝐴 = (𝐿𝑟 + 𝑀) 𝑖𝐴 + 𝑛𝐶𝐿𝐿𝐶 ∙ 𝑀 𝑖 (22)
𝑑𝑡 𝑑𝑡 𝐵 is able to meet the maximum voltage gain requirement.
However, the operating frequency range for the converter will
𝑑 𝑑 be very wide. A small Lm and a small Ln can narrow down the
𝑣𝐵 = 𝑛𝐶𝐿𝐿𝐶 ∙ 𝑀 𝑖 + 𝑛𝐶𝐿𝐿𝐶 2 ∙ 𝑀 𝑖 (23)
𝑑𝑡 𝐴 𝑑𝑡 𝐵 operating frequency range, however it will result in larger
magnetics. So, there is a trade-off between the size of the
These four equations (20) - (23) can be solved for nCLLC, Lr converter and the operating switching frequency range.
and M. 1.4
Ln = 10
(𝐿′2 + 𝐿𝑚 ) Ln = 7.5
𝑛𝐶𝐿𝐿𝐶 = (24) 1.2
𝐿𝑚
Ln = 5
Ln = 2.5
1 Ln = 1
𝐿𝑚 2
Voltage Gain ( Vo / Vi )
𝑀= (25)
(𝐿′2 + 𝐿𝑚 ) 0.8
(𝐿1 + 𝐿𝑚 ) ∙ (𝐿′2 + 𝐿𝑚 ) − 𝐿𝑚 2 0.6
𝐿𝑟 = (26)
(𝐿′2 + 𝐿𝑚 ) 0.4
So, the equivalent CLLC-type resonant converter becomes, 0.2
v1 - i1 iprim i2 v2 -
+
+ Io +
C1 Lr C2 vCf 0
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
+ + - Cf
vCD Irect
Frequency (Hz) 5
vAB M RL Vo x 10
im
- - iCf Rc (a) Lm = 300 µH, fres = 100 kHz and RL = 80 Ω

-
nCLLLC : nCLLC 2
Ln = 10
Fig. 10. Equivalent circuit diagram for the converter in Fig. 1 with a CLLC- 1.8 Ln = 7.5
type resonant network Ln = 5
1.6
The two resonant networks have same terminal voltages and Ln = 2.5
Ln = 1
loop currents. So, the gain curves and the voltage and current 1.4
waveforms shown in Figs. 4-6 are identical for both resonant 1.2
networks.
1
0.8
IV. DESIGN EXAMPLE
0.6
As a design example, a 3.5 kW bidirectional converter is to
be designed with a dc bus voltage of 400 V and an output 0.4
battery voltage of 250 V ~ 450 V. So, the voltage gain 0.2

requirement of the converter in the BCM is 0.625 ~ 1.125. The
0
voltage gain requirement in the RM is 0.89 ~ 1.60. The nominal 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
5
battery voltage is 400 V. And, the primary-side series resonant Frequency (Hz) x 10
frequency is chosen to be 100 kHz. (b) Lm = 200 µH, fres = 100 kHz and RL = 80 Ω
For a nominal battery voltage of 400 V, the transformer Fig. 11. Voltage gain curves for different values of Ln when Lm = 300 µH and
200 µH.
turns ratio comes out to be 1. For a resonant frequency of 100
3.5
Ln = 10
Ln = 7.5
3
Ln = 5 Gain: 0.89 ~ 1.6
Ln = 2.5
2.5 Ln = 1
40 kHz ~ 110 kHz

2
1.5
Fig. 14. Voltage gain curves for the designed converter operating in the RM.
1
V. EXPERIMENTAL RESULTS
0.5
To validate the converter design, a 3.5 kW bidirectional
resonant converter was built in lab. Both resonant networks,
0
CLLLC and CLLC are built. For a CLLLC configuration, the
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Frequency (Hz)
x 10
5 inductances in the resonant network consist of L1, L2 and Lm.
Fig. 12. Voltage gain curves for converter with Lm = 100 µH, fres = 100 kHz And, for a CLLC configuration, the inductances are Lr and M.
and RL = 80 Ω. The values of these inductances are listed in Table (I). The
An Lm of 100 µH and an Ln equal to 5 can meet voltage gain resonant capacitance in the dc bus side consists of two
requirements in both directions. And with these inductances, capacitors each 68 nF, 5PT46L683, in parallel. And in the
the operating switching frequency range is not very wide. So, battery side, two capacitors each of 100 nF, 5PT46L104, are in
the resonant inductances come out to be, parallel. Experiments showed that the rectifying diodes having
𝐿1 = 𝐿2 = 20 𝜇𝐻 longer reverse recovery time affected the converter gain curves
C1 can be calculated from the resonant frequency and the in the regeneration. Infineon IGBTs, IKW40N65F5, have better
resonant inductance. It comes out to be, antiparallel diodes as compared to the body-diodes of
1 MOSFETs. So, these IGBTs were selected as switches QA ~ QD.
𝐶1 = ≈ 125 𝑛𝐹 For switches QE ~ QH, Fairchild MOSFETs, FCH041N65F
𝐿1 (2𝜋𝑓𝑟𝑒𝑠 )2
were selected.
To make the gain curves monotonically decreasing and to
For experiments, the programmable electronic load, BK
meet the voltage gain requirement in both modes, Cn was
Precision 8526 5000W, is used. In the BCM, the e-load is
chosen to be 1.6. So C’2 comes out to be,
programmed as a battery load whose voltage is varied from
𝐶′2 = 1.6 × 125 𝑛𝐹 = 200 𝑛𝐹 250V to 450V. In the RM, the e-load is programmed as a current
This value of C’2 will make the secondary side series source whose current is varied from 0.5A to 8.5A to emulate
resonant frequency to be 80 kHz. Since, nCLLLC is equal to 1. So, the ac-dc stage. The circuit parameters for the designed
L2 and C2 are equal to L’2 and C’2 respectively. For the CLLC- converter are listed in table (I). And, table (II) compares the
type resonant network, Lr, M and nCLLC can be calculated using magnetics in both CLLLC-type and CLLC-type resonant
equations (24) – (26). networks. Fig. 15 shows the 3.5 kW CLLLC-type converter
𝐿𝑟 = 36.67 𝜇𝐻 build in the lab.
𝑀 = 83.33 𝜇𝐻 TABLE I. CIRCUIT PARAMETERS
𝑛𝐶𝐿𝐿𝐶 = 1.2
The voltage gain curves for the designed converter in the VDC 400 V
BCM are shown in Fig. 13, while the voltage gain curves for the L1 18.87 μH
designed converter in the RM are shown in Fig. 14.
L2 19.16 μH
Gain: C1 2 x 68 nF
0.625 ~ 1.125
C2 2 x 100 nF
Lm 94.2 μH
85 kHz ~ 145 kHz
nCLLLC 1
Lr 34.8 μH
M 78.28 μH
Fig. 13. Voltage gain curves for the designed converter operating in the BCM. nCLLC 1.2
These gain curves show that the designed converter meets the CDC 30 μF
voltage gain requirement in both directions. These gain curves Cf 30 μF
give information about the operating frequency range of the
VBatt (e-load in BCM) 250 V ~ 450 V
converter. The operating frequency range for the converter
operating in the BCM is 85 kHz ~ 145 kHz. And, the operating iDC (e-load in RM) 0.5 A ~ 8.5 A
frequency range for the converter operating in the RM is 40 kHz QA ~ QD IKW40N65F5
~ 110 kHz. QE ~ QH FCH041N65F
higher than the normal operating frequency range at the start-

TABLE II. MAGNETICS COMPARISON FOR CLLLC AND up.
CLLC-TYPE RESONANT CONVERTERS In the BCM, the ac-dc stage charges the dc bus capacitor.
Once the dc bus voltage reaches 380 V, the dc-dc stage is turned
CLLLC-type CLLC-type on. The e-load voltage takes some time to reach the rated
resonant resonant
voltage. During this time, the operating switching frequency is
converter converter
kept constant at 200 kHz to limit the surge current. Once the e-
Resonant inductor core ETD 49/25/16 ETD 49/25/16 load voltage is 250 V, the converter can be operated normally
– 3C95 – 3C95 with its output current-loop closed. Fig. 16 shows the converter
No. of turns in each 12 15 start-up in the BCM. It can be seen that the start-up current is
resonant inductor 23 A, which is slightly higher than the peak steady-state current
Air-gap in resonant 1.85 mm 1.56 mm of 20 A.
inductor cores
vAB 20 ms vBatt
Weight of each 250 g 250 g
resonant inductor i1 i2 250 V
Volume of each 100 cm3 100 cm3 400 V
resonant inductor
Transformer core EE 65/32/27 – EE 65/32/27 – 23 A
3C95 3C95
No. of turns in 18:18 15:18
transformer Open-loop ( fsw = 200 kHz) Closed-loop
Air-gap in transformer 1.84 mm 1.41 mm Fig. 16. Converter start-up in the BCM.
cores
Weight of transformer 800 g 800 g In the RM, the battery charges the dc bus at the start-up.
Once the dc bus voltage reaches 380 V, the ac-dc stage is turned
Volume of transformer 215 cm3 215 cm3
on. The start-up of the converter in the RM is shown in Fig. 17.
At the start of the start-up process, the converter is operated in
It can be seen in table (II) that the total volume of the
an open-loop at a switching frequency of 200 kHz. Once the dc
magnetics in the CLLLC-type resonant converter is 415 cm3,
bus voltage reaches 250 V, the converter is operated in the
whereas in the CLLC-type resonant network, it is 315 cm3. And,
closed-loop with the dc bus voltage reference ramped up very
the total weight of the magnetics in the CLLLC-type resonant
slowly to 400 V. It can be seen that the start-up current is not
converter is 1300 g, whereas in the CLLC-type resonant
very high. It is 30A for a worst-case of battery voltage of 450
converter, it is only 1050 g. So, the volume and the weight of
V. The converter output voltage can go very high at no-load
magnetics in the CLLC-type resonant converter are much lower
condition. To limit the output voltage, a burst mode is
as compared to the volume and the weight of the magnetics in
implemented. This burst mode keeps the dc bus voltage at 420
the CLLLC-type resonant converters.
AC – DC stage DC – DC stage
V at no-load conditions.
vCD
DSP Board
for DC-DC
stage vDC
Cf 30 A
L1
10.5"
Transormer 450 V i2 i1 420 V
L2
CDC Closed Loop
DSP Board Open Loop ( fsw = 200 kHz) 500 ms
for AC-DC Burst mode
13.25"
stage Fig. 17. Converter start-up in the RM at the worst-case of Vbatt = 450 V.
Fig. 15. 3.5 kW bidirectional battery charger build in lab. B. Converter Operation in the BCM
A. Converter Start-up in BCM and RM
In the BCM, the switches QA ~ QD act as a high-frequency
One of the major issues with the resonant converters is the inverter while the body-diodes of the switches QE ~ QH act as a
start-up surge current. In most of the resonant converters, the rectifier bridge charging the output battery. The output voltage,
output filter capacitor short-circuits the magnetizing inductance output current and input impedance phase versus the frequency
at the start-up. So, the input impedance is very small resulting for the designed converter are plotted in Fig. 18.
in a huge start-up current. In this topology, there is an inductor
and a capacitor in the secondary side. The output capacitor does
not short the resonant network making the input impedance
always inductive. So, the converter never loses ZVS in the
primary-side switches, even at the start-up. To limit the surge
current, the operating switching frequency is kept slightly
(a) VBatt = 250 V and IBatt = 10 A (Buck mode in Region 1)
Fig. 18. Output voltage, output current and input impedance phase versus
operating switching frequency for converter operating in the BCM.
(b) VBatt = 350 V and IBatt = 10 A (Buck mode in Region 1)
The output charging current versus the battery voltage for

the converter operating in the BCM is shown in Fig. 19. During
the constant current mode, a constant current charges the output
battery. The output current is limited to 10 A for the lower
battery voltages. For higher battery voltages, the charging
current is reduced to keep the output power at 3.5 kW.
Battery Current
10 A
8.75 A
7.5 A
250 V 300 V 350 V 400 V 450 V

Battery Voltage (c) VBatt = 450 V and IBatt = 7.5 A (Boost mode in Region 2)
Fig. 19. Battery current versus the battery voltage for the converter operating
Fig. 20. Voltages and currents for the converter operating in the BCM with
in the BCM. VDC = 400 V,
Yellow = Primary-side bridge voltage, vAB,
Red = Primary-side current, i1, Blue = Secondary side bridge voltage, vCD, and
Fig. 20 shows the measured current and voltage waveforms Green = Secondary side current, i2
for the converter operating in the BCM under different battery
voltages. It can be seen that for a lower battery voltage, the gain of
the converter is less than 1. So, the converter operates in region
1, and switching frequency is higher than the fser. For a battery
voltage of 450 V, the converter gain is more than 1, and the
converter operates in Region 2 and the operating switching
frequency is lower than the fser.
Fig. 21 shows the power-stage measured efficiency for the
converter operating in the BCM. The solid line represents the
efficiency of the converter power-stage with a CLLLC-type
resonant network, while the dashed line represents the
efficiency of the power stage with a CLLC-type resonant
network. For lower battery voltages, the efficiency is lower as
the converter operates at the frequencies much higher than the
fser. The efficiency is maximum for the battery voltage of 400 V
as the gain of the converter is unity, and the converter operates
at the series resonant frequency. The peak power-stage
efficiency for the converter is 97.7 %.
98 Output Power
97.5
3.4 kW
97
Power Stage Efficiency (%)
96.5 2.8 kW
96
2.4 kW
95.5
2 kW
95
94.5
VBatt = 250 V 450 V 400 V 350 V 300 V 250 V
94 VBatt = 300 V Battery Voltage
93.5 VBatt = 350 V Fig. 23. Converter output power versus the battery voltage for the converter
VBatt = 400 V operating in the RM.
93
4 5 6 7 8 9 10
Output Current (A)
Fig. 24 shows the measured current and voltage waveforms
Fig. 21. Power-stage measured efficiency for different battery voltages
under different load conditions for converter operating in the BCM with VDC = for the converter operating in the RM under different load
400 V for both CLLLC (solid lines) and CLLC resonant converters (dashed conditions.
lines).
C. Converter Operation in the RM

In the RM, the switches QE ~ QH act as a high frequency
inverter while the anti-parallel diodes of the switches QA ~ QD
act as a rectifier bridge delivering power to dc bus. The output
voltage, output current and input impedance phase versus
frequency are plotted in Fig. 22.
(a) VBatt = 450 V and IDC = 8.5 A (Buck mode in Region 1)
Fig. 22. Output voltage, output current and input impedance phase versus
operating switching frequency for converter operating in RM.
In the RM, the converter keeps the dc bus voltage constant

for a wide range of battery voltages. In this mode, the converter
primary-side rms current, i2, can get very high for higher output
power conditions. So, to limit this current, the output power is
reduced at lower battery voltages. Converter output power
versus the battery voltage for the converter operating in the RM
is shown in Fig. 23.
(b) VBatt = 350 V and IDC = 7 A (Boost mode in Region 2)
Loss Breakdown (Battery Charging Mode)

140
120
100
80
60
40
20
0
Switches QA ~ Resonant Transformer Switches QE ~ Total Losses
QD Inductors (L1 QH
and L2)
CLLLC Configuration CLLC Configuration

(c) VBatt = 250 V and IDC = 5 A (Boost mode in Region 2)
Fig. 24. Voltages and currents for converter operating in the RM with VDC = Fig. 26. Loss breakdown for converter operating in BCM at VBatt = 350 V and
400 V, Io = 10A.
Yellow = Secondary side bridge voltage, vCD,
Red = Secondary side current, i2, Blue = Primary-side bridge voltage, vAB, and Loss Breakdown (Regeneration Mode)
Green = Primary-side current, i1
It can be seen that for higher battery voltages, the gain of 80

the converter is less than 1. So, the converter operates in region 60
1, and switching frequency is higher than the fser. For lower 40
battery voltages, the converter gain is more than 1, and the
20
converter operates in region 2 and the operating switching
0
frequency is lower than the fser. Switches QA ~ Resonant Transformer Switches QE ~ Total Losses
Fig. 25 shows the power-stage measured efficiency for QD Inductors (L1 QH
converter operating in the RM. It can be seen that the efficiency and L2)
for a CLLLC-type configuration is higher than the CLLC-type CLLLC Configuration CLLC Configuration
configuration in the RM. The peak efficiency for the converter
with the CLLLC-type configuration is 98.10 %. While, the peak Fig. 27. Loss breakdown for converter operating in RM at VBatt = 400 V, VDC =
400 V and IDC = 8A.
efficiency in the CLLC-type configuration is 97.9 %.
100
VI. CONCLUSIONS
98
The CLLLC-type resonant converter is similar to an LLC-
96
type resonant converter with an extra inductor and capacitor in
Efficiency of DC-DC stage (%)
VBatt = 250 V
94 the secondary-side. Soft-switching can be ensured in all the
VBatt = 350 V
92 switches without additional circuitry. Because of soft-switching
VBatt = 450 V
in all switches, very high-frequency operation is possible thus
90
the size of the magnetics and the capacitors can be made small.
88 In this paper, first an equivalent model for the CLLLC-type
86 converter was derived for the steady-state analysis. This model
was used to get the voltage and current gain curves for any load
84
and line conditions. These gain curves verify the design of the
82 power-stage, and give information about the operating
80 frequency range of the converter. Then, the design
0 1 2 3 4 5 6 7 8
Output Current (A)
methodology for a CLLLC-type configuration was presented in
Fig. 25. Power-stage measured efficiency for different battery voltages detail. Design of the converter includes determining the
under different load conditions for converter operating in the RM for both transformer turns ratio, determining the magnetizing inductance
CLLLC (solid lines) and CLLC resonant converter (dashed lines). based on ZVS condition, and determining the resonant
The losses in the power-stage can be divided into losses in inductances and capacitances. Then, the CLLC-type resonant
the active switches, losses in the rectifying diodes and losses in network was derived from the CLLLC-type network.
the magnetics. Fig. 26 shows the loss breakdown for the Major contributions of this paper include:
converter operating in the BCM at 3.5 kW output load. The
losses are slightly lower for the CLLC configuration resulting · To propose a design methodology for a CLLLC-type
in higher efficiency. Fig. 27 shows the loss breakdown for the bidirectional resonant converter for a battery charging
applications. The charging process for a battery
converter operating in the RM at 3.2 kW output load. The losses
usually contains several stages, and the output voltage
are slightly higher for CLLC configuration resulting in slightly
and the load power change significantly during the
lower efficiency. whole charging process. The design methodology
proposed in this paper takes these processes into [8] P. Junsung and C. Sewan, "Design and Control of a Bidirectional
Resonant DC-DC Converter for Automotive Engine/Battery Hybrid
account. This design methodology will ensure that the
Power Generators," Power Electronics, IEEE Transactions on, vol.
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decreasing for all load and line conditions in both [9] F. Martin Ibanez, J. Martin Echeverria, J. Vadillo, and L. Fontan, "A
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designed and built in lab following the guidelines in the [13] Y. Wensong and L. Jih-Sheng, "Ultra high efficiency bidirectional
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Design of Bidirectional DC - DC Resonant Converter For Vehicle-to-Grid (V2G) Applications

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This article has been accepted for publication in a future issue of this journal, but has not been

Design of Bidirectional DC- DC Resonant

 literature [4-15]. The main focus in these converters is on

R ECENTLY, electric vehicles (EVs) and plug-in hybrid

CLLLC-type network to reduce the size and the cost of the + Io +

operating in the battery charging mode is developed for the - - iCf Rc -

𝑖𝑟𝑒𝑐𝑡 = |𝑖2 | (3) 2

VAB I_L1 I_Lm

Lr kHz, a dead-time of 200 nSec and a switch output capacitance

(𝐿1 + 𝐿𝑚 ) ∙ (𝐿′2 + 𝐿𝑚 ) − 𝐿𝑚 2 0.6

So, the equivalent CLLC-type resonant converter becomes, 0.2

- - iCf Rc (a) Lm = 300 µH, fres = 100 kHz and RL = 80 Ω

battery voltage of 250 V ~ 450 V. So, the voltage gain 0.2

40 kHz ~ 110 kHz

higher than the normal operating frequency range at the start-

(a) VBatt = 250 V and IBatt = 10 A (Buck mode in Region 1)

The output charging current versus the battery voltage for

250 V 300 V 350 V 400 V 450 V

C. Converter Operation in the RM

(a) VBatt = 450 V and IDC = 8.5 A (Buck mode in Region 1)

In the RM, the converter keeps the dc bus voltage constant

(b) VBatt = 350 V and IDC = 7 A (Boost mode in Region 2)

Loss Breakdown (Battery Charging Mode)

CLLLC Configuration CLLC Configuration

It can be seen that for higher battery voltages, the gain of 80

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