An approach to deal with packaging in power electronics

Current packaging technology in power electronics is based on assembling pre-manufactured discrete components. Each component consists of a number of parts, manufactured in a variety of manufacturing processes. This has resulted in a diversity of construction parts and mutually incompatible manufacturing processes in a typical power electronic converter and has brought power electronics to the edge where it becomes extremely difficult to reduce the cost and size of power electronic converters. This also makes integration of power electronic converters difficult. In this paper, we present a way to improve the physical construction of power electronic converters by increasing level of integration and using multifunctional construction parts. integration and packaging are two important aspects of physical construction of power electronic converters. Both of them and their mutual relationship are discussed in the paper. Three quantities intended to evaluate integration level and volumetric utilization namely functional elements integration level, K/sub I/; packaging elements integration level K/sub P/; and volumetric packaging efficiency /spl eta//sub v/ are introduced. Based on these values, a number of techniques to increase the integration level are presented. A design process in the form of a flowchart intended to implement these techniques in concrete design cases is presented.     

Solid-state control of electric drives

A tutorial review of the dc and ac electric-drive field is presented. The goal is to present fundamental concepts, principle concerns, and key developments in electric-drive technology. Principles of ac and dc power converters and ac and dc motors are presented. Then the combination of the converter and motor to provide a complete drive system is discussed along with drive-system characteristics and methods for analyzing performance. Finally, some application guidelines for both ac and dc systems are given.     

Buck-boost converter feedback controller design via evolutionary search

Buck-boost converters are switched power converters. The model of the converter system varies from the ON state to the OFF state and hence traditional methods of controller design based on approximate transfer function models do not yield good dynamic response at different operating points of the converter system. This article attempts to design a feedback controller for a buck-boost type dc–dc converter using a genetic algorithm. The feedback controller design is perceived as an optimisation problem and a robust controller is estimated through an evolutionary search. Extensive simulation and experimental results provided in the article show the effectiveness of the new approach.     

A Three-Level Full-Bridge Zero-Voltage Zero-Current Switching Converter With a Simplified Switching Scheme

Multilevel dc–dc converters making use of high-frequency transformers are suitable for integration in solid-state solutions for applications in electric power distribution systems. This paper presents a simplified switching scheme for three-level full-bridge dc–dc converters that enables zero-voltage and zero-current switching of all the main power devices. It describes the main operational modes and design equations of the converter as well as provides simulation and experimental results to demonstrate the feasibility of the proposed ideas.      

PWM-PD multiple output DC/DC converters: operation and control-loop modeling

In this paper, PWM-PD multiple output dc/dc converters are presented. Operation analysis and power block design are shown. Furthermore, a small-signal model is developed for the PWM-PD multiple output dc/dc converters working in continuous conduction mode. The control-block is presented and the closed-loop circuit performances, such as the line, load and cross regulation, are obtained analytically. Finally, experimental results for a PWM-PD converter, with three fully regulated outputs and with transformer, are shown.     

A New Method of Integration Control With Instantaneous Current Monitoring for Class D Series-Resonant Converter

In this paper, the application of the integration control method for class D transistor voltage source series-resonant converters used as dc/dc and dc/ac converters is presented. First, the integration control of the signal as a combination of the resonant frequency and its subharmonics (subharmonic integration control) is discussed. Second, the modulation density of the pulses shorting the bridge diagonal for one current half wave (semi wave integral pulse density modulation) is explained. A detailed control circuit operation, referred to as the four basic algorithms of the resonant current control, is given. The method for the calculation of the value and sequence of the current increments for a dc/dc converter is presented. The results of computer simulations and laboratory experiments demonstrate that the proposed methods allow controlling the converter output quantities fulfilling soft switching conditions (zero-current switching) and provide higher efficiency in comparison to other known methods     

Small-Signal Dynamic Analysis of Regulated Class E DC/DC Converters

Class E dc/dc converters can operate at high switching frequencies with very low switching power losses. Using commercially available power transistors and diodes, Class E converters can operate at switching frequencies in the low-MHz range, with efficiencies of about 85 percent. Previous papers dealt with the circuit parameter values needed to obtain high-efficiency operation and output-voltage regulation, and with the static control characteristics of the Class E dc/dc converter cell. The analysis is extended to include the dynamic control characteristics and further information about the static characteristics. The theoretical predictions are verified by experimental measurements on a 40-W 1.5-MHz converter.     

Flyboost power factor correction cell and a new family of single-stage AC/DC converters

A novel power factor correction (PFC) cell, called flyboost, is presented. The proposed PFC cell combines power conversion characteristics of conventional flyback and boost converters. Based on the flyboost PFC cell, a new family of single-stage (S/sup 2/) ac/dc converters can be derived. Prominent features of newly derived S/sup 2/ converters include: three power conversions, i.e., boost, flyback, and another isolated dc/dc power conversions are simultaneously realized that typically uses only one power switch and one simple controller; part of the power delivered to the load is processed only once; bulk capacitor voltage can be clamped to the desired level; and capable of operating under continuous current mode. Experimental results on example converters verify that while still achieving high power factor and tight output regulation, the flyboost PFC cell substantially improve the efficiency of the converter.     

Performance Comparison of Single-Stage Three-Level Resonant AC/DC Converter Topologies

In this paper, the performance of different three-level resonant converters is studied for single-stage power factor correction operation. These converters are suitable for power ranges higher than that in the currently available single-stage converters, due to their high efficiency and reduced component stresses. All the converters presented here are characterized by their ability to regulate the output voltage as well as the dc bus voltage. This leads to lower voltage stresses, wider input voltage range, higher output power applications, and improved efficiencies compared to existing single-stage topologies. Due to the availability of more degrees of freedom in the presented converters, two types of control strategies can be used for this purpose: variable frequency asymmetrical pulsewidth modulation control and variable frequency phase-shift modulation control. Three resonant converters will be studied in this paper and their performances as well as the applicability of the aforementioned control methods for each converter are compared. A 2.3-kW, 48-V converter with input voltage range of 90-265 V_rms is used to study the performance of each case.     

Accurate Power Loss Model Derivation of a High-Current Dual Active Bridge Converter for an Automotive Application

An accurate power loss model for a high-efficiency dual active bridge converter, which provides a bidirectional electrical interface between a 12-V battery and a high-voltage (HV) dc bus in a fuel cell car, is derived. The nominal power is 2 kW, the HV dc bus varies between 240 and 450 V, and the battery voltage range is between 11 and 16 V. Consequently, battery currents of up to 200 A occur at nominal power. In automotive applications, high converter efficiency and high power densities are required. Thus, it is necessary to accurately predict the dissipated power for each power component in order to identify and to properly design the heavily loaded parts of the converter. In combination with measured efficiency values, it is shown that conventional converter analysis predicts substantially inaccurate efficiencies for the given converter. This paper describes the main reasons why the conventional method fails and documents the different steps required to predict the power losses more accurately. With the presented converter prototype, an efficiency of more than 92% is achieved at an output power of 2 kW in a wide input/output voltage range.      

A Line-Interactive Single-Phase to Three-Phase Converter System

This paper describes a line-interactive single-phase to three-phase converter. A typical application is in rural areas supplied by a single-wire with earth return system. The traditional objective of feeding a three-phase induction motor is not anymore the main concern for such conversion. Due to the evolution of the farm technology, some of the local loads (as electronic power converters, computers, communication equipments, etc) require high power quality that is intended as sinusoidal, symmetrical, and balanced three-phase voltage. Additionally, to maximize the power from the feeder, the system provides a unity power factor to the grid. A three-phase voltage source inverter-pulsewidth modulation converter is used for this purpose. The power converter processes a fraction of the load power and the energy necessary to regulate the dc link voltage. As it does not need to supply active power, it is not necessary to have a source at the dc side. However, if island mode operation is needed, a dc source must be available at the dc link to supply the load. The control strategy, design criteria, and experimental results are presented     

Magnetics on silicon: an enabling technology for power supply on chip

Data from the ITRS2003 roadmap for 2010 predicts voltages for microprocessors in hand-held electronics will decrease to 0.8V with current and power increasing to 4A and 3W, respectively. Consequently, low power converters will move to multimegahertz frequencies with a resulting reduction in capacitor and inductor values by factors of 5 and 20, respectively. Values required at 10 MHz, for a low power buck converter, are estimated at 130 nH and 0.6 uF, compatible with the integration of magnetics onto silicon and the concept of power supply-on-chip (PSOC). A review of magnetics-on-silicon shows that inductance values of 20 to 40nH/mm/sup 2/ can be achieved for winding resistances less than 1/spl Omega/. A 1-/spl mu/H inductance can be achieved at 5 MHz with dc resistance of 1/spl Omega/ and a Q of four. Thin film magnetic materials, compatible with semiconductor processing, offer power loss density that is lower than ferrite by a factor of 5 at 10 MHz. Other data reported includes, lowest dc resistance values of 120 m/spl Omega/ for an inductance of 120 nH; highest Q of 15 for an inductance of 350 nH and a current of 1 A for a 1- /spl mu/H inductor. Future technology challenges include reducing losses using high resistivity, laminated magnetic materials, and increasing current carrying capability using high aspect-ratio, electroplated copper conductors. Compatible technologies are available in the power switch, control, and packaging space. Integrated capacitor technology is still a long-term challenge with maximum reported values of 400 nF/cm/sup 2/.     

PCB integrated inductors for low power DC/DC converter

This paper discusses the use of printed circuit board (PCB) integrated inductors for low power DC/DC buck converters. Coreless, magnetic plates and closed core structures are compared in terms of achievable inductance, power handling and efficiency in a footprint of 10 /spl times/ 10 mm/sup 2/. The magnetic layers consist of electroplated NiFe, so that the process is fully compatible with standard PCB process. Analytic and finite element method (FEM) methods are applied to predict inductor performance for typical current waveforms encountered in a buck converter. Conventional magnetic design procedures are applied to define optimum winding and core structures for typical inductor specifications. A 4.7 /spl mu/H PCB integrated inductor with dc current handling of up to 500 mA is presented. This inductor is employed in a 1.5 W buck converter using a commercial control integrated circuit (IC). The footprint of the entire converter measures 10 /spl times/ 10 mm/sup 2/ and is built on top of the integrated inductor to demonstrate the concept of integrated passives in power electronic circuits to achieve ultra flat and compact converter solutions.     

Emulating DC constant power load: a robust sliding mode control approach

This article presents emulation of a programmable power electronic, constant power load (CPL) using a dc/dc step-up (boost) converter. The converter is controlled by a robust sliding mode controller (SMC). A novel switching surface is proposed to ensure a required power sunk by the converter. The proposed dc CPL is simple in design, has fast dynamic response and high accuracy, and offers an inexpensive alternative to study converters for cascaded dc distribution power system applications. Furthermore, the proposed CPL is sufficiently robust against the input voltage variations. A laboratory prototype of the proposed dc CPL has been developed and validated with SMC realised through OPAL-RT platform. The capability of the proposed dc CPL is confirmed via experimentations in varied scenarios.     

A family of high power density unregulated bus converters

This paper begins by reviewing current bus converters and exploring their limitations. Next, a family of inductor-less bus converters is proposed to overcome the limitations. In the new bus converters, magnetizing current is used to achieve zero-voltage-switching (ZVS) turn-on for all switches. The resonant concept is used to achieve nearly zero-current-switching (ZCS) turn-off for the primary switches and no body diode loss for the synchronous rectifiers (SRs). Meanwhile, the self-driven method can be easily applied to save drive loss of SRs. Based on these concepts, a full-bridge bus converter is built in the quarter-brick size to verify the analysis. The experimental results indicate that it can achieve 95.5% efficiency at 500-W, 12-V/45-A output. Compared with industry products, this topology can dramatically increase the power density. These concepts are also applied to nonisolated dc/dc converters. As an example, a resonant Buck converter is proposed and experimentally demonstrated.     

Framework and Research Methodology of Short-Timescale Pulsed Power Phenomena in High-Voltage and High-Power Converters

Various short-timescale transients exist in power electronic converters, particularly in high-voltage and high-power systems. The timescales of these transients are from nanoseconds to microseconds, including a switching transition of power semiconductor devices, commutating processes, and drive signal transmissions. These transient processes directly affect the performance and reliability of power electronic systems. Therefore, it is necessary to study these short-timescale processes. Based on two high-power prototype power converters, a 6000-V/1250-kW three-level adjustable-speed drive and a 10-kW/600-V dc–dc converter, this paper studies the various abnormal behaviors of the converters that occurred during the operation of these converters. Dead bands and accumulated switching errors are also investigated. A combined microscopic pulsed power and macroscopic control strategy was proposed for the design of power electronic converters. Three new concepts for power electronic converters are introduced and validated in this paper: 1) sneak pulse; 2) energy dead band; and 3) transient commutating topology.      

Analysis and Design for a Novel Single-Stage High Power Factor Correction Diagonal Half-Bridge Forward AC–DC Converter

By means of components placement, the buck-boost and diagonal half-bridge forward converters are combined to create a novel single-stage high power factor correction (HPFC) diagonal half-bridge forward converter. When both the PFC cell and dc–dc cell operate in DCM, the proposed converter can achieve HPFC and lower voltage stress of the bulk capacitor. The circuit analysis of the proposed converter operating in$ DCM+ DCM$mode is presented. In order to design controllers for the output voltage regulation, the ac small-signal model of the proposed converter is derived by the averaging method. Based on the derived model, the proportional integral (PI) controller and minor-loop controller are then designed. The simulation and experimental results show that the proposed converter with the minor-loop controller has faster output voltage regulation than that with the PI controller despite the variations of line voltage and load. Finally, a 100-W prototype of the proposed ac–dc converter is implemented and the theoretical result is experimentally verified.     

Feed-Forward Space Vector Modulation for Single-Phase Multilevel Cascaded Converters With Any DC Voltage Ratio

Modulation techniques for multilevel converters can create distorted output voltages and currents if the dc-link voltages are unbalanced. This situation can be avoided if the instantaneous dc voltage error is not taken into account in the modulation process. This paper proposes a feed-forward space vector modulation method for a single-phase multilevel cascade converter. Using this modulation technique, the modulated output voltage of the power converter always generates the reference determined by the controller, even in worst case voltage unbalance conditions. In addition, the possibility of optimizing the dc voltage ratio between the H-bridges of the power converter is introduced. Experimental results from a 5-kVA prototype are presented in order to validate the proposed modulation technique.      

Design and analysis of a novel zero-voltage-transition interleaved boost converter for renewable power applications

High-efficiency stepping up operation is an important feature of the converters used in renewable power applications due to the low voltage level of photo-voltaic arrays and fuel cells. Decreasing the switching losses of the converters is an effective solution for increasing the converter efficiency, especially in high-power applications. This article presents a novel zero-voltage-transition (ZVT) interleaved dc–dc boost converter that can be used in renewable power sources to reduce switching losses. The auxiliary circuit used in the proposed converter is composed of only one auxiliary switch and a minimum number of passive components without an important increase in the cost and complexity. The main advantage of the proposed converter is that it not only provides ZVT in the boost switches but also provides soft switching in the auxiliary switch. Another advantage of the proposed topology is that the semiconductor devices used in the converter do not have any additional voltage or current stresses. Also, it has a simple structure, low cost and ease of control. In this article, a detailed steady-state analysis of the proposed converter is presented. The theoretical analysis is verified via simulation and experimental studies which are in very good agreement.