This dissertation investigates digital controller and switch mode power supply design for super high-speed permanent magnet synchronous motors (PMSM). The PMSMs are a key component for the miniaturic cryocooler that is currently under development at the University of Central Florida with support from NASA Kennedy Space Center and the Florida Solar Energy Center. Advanced motor design methods, control strategies, and rapid progress in semiconductor technology enables production of a highly efficient digital controller. However, there are still challenges for such super high-speed controller design because of its stability, high-speed, variable speed operation, and required efficiency over a wide speed range. Currently, limited research, and no commercial experimental analysis, is available concerning such motors and their control system design. The stability of a super high-speed PMSM is an important issue particularly for open-loop control, given that PMSM are unstable after exceeding a certain applied frequency. In this dissertation, the stability of super high-speed PMSM is analyzed and some design suggestions are given to maximize this parameter. For ordinary motors, the V/f control curve is a straight line with a boost voltage because the stator resistance is negligible and only has a significant effect around the DC frequency. However, for the proposed super high-speed PMSM the situation is quite different because of the motor's size. The stator resistance is quite large compared with the stator reactive impedance and cannot be neglected when employing constant a V/f control method. The challenge is to design an optimal constant V/f control scheme to raise efficiency with constant V/f control. In the development, test systems and prototype boards were built and experimental results confirmed the effectiveness of the dissertation system.

Laser tracking systems are an important aspect of the NASA space program, in particular for conducting research in relation to satellites and space port launch vehicles. Often, launches are conducted at remote sites which require all of the test equipment, including the laser tracking systems, to be portable. Portable systems are more susceptible to environmental disturbances which affect the overall tracking resolution, and consequently, the resolution of any other experimental data being collected at any given time. This research characterizes the optical coupling between two systems in a Mobile Experimental Laser Tracking system and evaluates several control solutions to minimize disturbances within this coupling. A simulation of the optical path was developed in an extensible manner such that different control systems could be easily implemented. For an initial test, several PID controllers were utilized in parallel in order to control mirrors in the optical coupling. Despite many limiting factors of the hardware, a simple proportional control performed to expectations. Although a system implementation was never field tested, the simulation results provide the necessary insight to develop the system further. Recommendations were made for future system modifications which would allow an even higher tracking resolution.

To relieve energy shortage and environmental pollution issues, renewable energy, especially PV energy has developed rapidly in the last decade. The micro-inverter systems, with advantages in dedicated PV power harvest, flexible system size, simple installation, and enhanced safety characteristics are the future development trend of the PV power generation systems. The double-stage structure which can realize high efficiency with nice regulated sinusoidal waveforms is the mainstream for the micro-inverter. This thesis studied a double stage micro-inverter system. Considering the intermittent nature of PV power, a PFC was analyzed to provide additional electrical power to the system. When the solar power is less than the load required, PFC can drag power from the utility grid. In the double stage micro-inverter, the DC/DC stage was realized by a LLC converter, which could realize soft switching automatically under frequency modulation. However it has a complicated relationship between voltage gain and load. Thus conventional variable step P&O MPPT techniques for PWM converter were no longer suitable for the LLC converter. To solve this problem, a novel MPPT was proposed to track MPP efficiently. Simulation and experimental results verified the effectiveness of the proposed MPPT. The DC/AC stage of the micro-inverter was realized by a BCM inverter. With duty cycle and frequency modulation, ZVS was achieved through controlling the inductor current bi-directional in every switching cycle. This technique required no additional resonant components and could be employed for low power applications on conventional full-bridge and half-bridge inverter topologies. Three different current mode control schemes were derived from the basic theory of the proposed technique. They were referred to as Boundary Current Mode (BCM), Variable Hysteresis Current Mode (VHCM), and Constant Hysteresis Current Mode (CHCM) individually in this paper with their advantages and disadvantages analyzed in detail. Simulation and experimental iv results demonstrated the feasibilities of the proposed soft-switching technique with the digital control schemes. The PFC converter was applied by a single stage Biflyback topology, which combined the advantages of single stage PFC and flyback topology together, with further advantages in low intermediate bus voltage and current stresses. A digital controller without current sampling requirement was proposed based on the specific topology. To reduce the voltage spike caused by the leakage inductor, a novel snubber cell combining soft switching technique with snubber technique together was proposed. Simulation and experimental waveforms illustrated the same as characteristics as the theoretical analysis. In summary, the dissertation analyzed each power stage of photovoltaic micro-inverter system from efficiency and effectiveness optimization perspectives. Moreover their advantages were compared carefully with existed topologies and control techniques. Simulation and experiment results were provided to support the theoretical analysis.

This work is focused on exploring advanced solutions for space power management and distribution (PMAD) systems. As spacecraft power requirements continue to increase, paralleled by the pressures for reducing cost and overall system weight, power electronics engineers will continue to face major redesigns of the space power systems in order to meet such challenges. Front-end PMAD systems, used to interface the solar sources and battery backup to the distribution bus, need to be designed with increased efficiency, reliability, and power density. A new family of integrated single-stage power converter structures is introduced here. This family allows the interface and control of multiple power sources and storage devices in order to optimize utilization of available resources. Employing single-stage power topologies, these converters control power flow efficiently and cost-effectively. This is achieved by modifying the operation and control strategies of isolated soft-switched half-bridge and full-bridge converters--two of the most popular two-port converter topologies. These topologies are reconfigured and utilized to realize three power processing paths. These paths simultaneously utilize the power devices, allowing increased functionality while promising reduced losses and enhanced power densities. Each of the proposed topologies is capable of performing simultaneous control of two of its three ports. Control objectives include battery or ultra-capacitor charge regulation, solar array maximum power point tracking (MPPT), and/or bus voltage regulation. Another advantage of the proposed power structure is that current engineering design concepts can be used to optimize the new topologies in a fashion similar to the mother topologies. This includes component selection and magnetic design procedures, as well as achieving soft-switching for increased efficiency at higher switching frequencies. Galvanic isolation of the load port through high-frequency transformers provides design flexibility for high step-up/step-down conversion ratios. It further allows the converters to be used as power electronics building blocks (PEBB) with outputs connected in different series/parallel combinations to meet different load requirements. Utilizing such converters promises significant savings in size, weight, and costs of the power management system as well as the devices it manages. Chapter 1 of this dissertation provides an introduction to the requirements, challenges, and trends of space PMAD. A review of existing multi-port converter technologies and digital control techniques is given in Chapter 2. Chapter 3 discusses different PMAD system architectures. It outlines the basic concepts used for PMAD integration and discusses the potential for improvement. Chapters 4 and 5 present and discuss the operation and characteristics of three different integrated multi-port converters. Chapter 6 presents improved methods for practical digital control of switching converters, which are especially useful in complex multi-objective controllers used for PMAD. This is followed by conclusions and suggested future work.

The power requirements for leading edge digital integrated circuits have become increasingly demanding. Power converter systems must be faster, more flexible, more precisely controllable and easily monitored. Meanwhile, in addition to control process, the new functions such as power sequencing, communication with other systems, voltage dynamic programming,load line specifications, phase current balance, protection, power status monitoring and system diagnosis are going into today's power supply systems. Digital controllers, compared withanalog controllers, are in a favorable position to provide basic feedback control as well as those power management functions with lower cost and great flexibility. The dissertation gives an overview of digital controlled power supply systems bycomparing with conventional analog controlled power systems in term of system architecture,modeling methods, and design approaches. In addition, digital power management, as one of the most valuable and "cheap" function, is introduced in Chapter 2. Based on a leading-edge digital controller product, Chapter 3 focuses on digital PID compensator design methodologies, design issues, and optimization and development of digital controlled single-phase point-of-load (POL)dc-dc converter. Nonlinear control is another valuable advantage of digital controllers over analogcontrollers. Based on the modeling of an isolated half-bridge dc-dc converter, a nonlinear control method is proposed in Chapter 4. Nonlinear adaptive PID compensation scheme is implemented based on digital controller Si8250. The variable PID coefficient during transients improves power system's transient response and thus output capacitance can be reduced to save cost. In Chapter 5, another nonlinear compensation algorithm is proposed for asymmetric flybackforward half bridge dc-dc converter to reduce the system loop gain's dependence on the input voltage, and improve the system's dynamic response at high input line. In Chapter 6, a unified pulse width modulation (PWM) scheme is proposed to extend the duty-cycle-shift (DCS) control, where PWM pattern is adaptively generated according to the input voltage level, such that the power converter's voltage stress are reduced and efficiency is improved. With the great flexibility of digital PWM modulation offered by the digital controller Si8250, the proposed control scheme is implemented and verified. Conclusion of the dissertation work and suggestions for future work in related directions are given in final Chapter.

The design optimization of DC-DC converters requires the optimum selection of several parameters to achieve improved efficiency and performance. Some of these parameters are load dependent, line dependent, components dependent, and/or temperature dependent. Designing such parameters for a specific load, input and output, components, and temperature may improve single design point efficiency but will not result in maximum efficiency at different conditions, and will not guarantee improvement at that design point because of the components, temperature, and operating point variations. The ability of digital controllers to perform sophisticated algorithms makes it easy to apply adaptive control, where system parameters can be adaptively adjusted in response to system behavior in order to achieve better performance and stability. The use of adaptive control for power electronics is first applied with the Adaptive Frequency Optimization (AFO) method, which presents an auto-tuning adaptive digital controller with maximum efficiency point tracking to optimize DC-DC converter switching frequency. The AFO controller adjusts the DC-DC converter switching frequency while tracking the converter minimum input power point, under variable operating conditions, to find the optimum switching frequency that will result in minimum total loss and thus the maximum efficiency. Implementing variable switching frequencies in digital controllers introduces two main issues, namely, limit cycle oscillation and system instability. Dynamic Limit Cycle Algorithms (DLCA) is a dynamic technique tailored to improve system stability and to reduce limit cycle oscillation under variable switching frequency operation. The convergence speed and stability of AFO algorithm is further improved by presenting the analysis and design of a digital controller with adaptive auto-tuning algorithm that has a variable step size to track and detect the optimum switching frequency for a DC-DC converter. The Variable-Step-Size (VSS) algorithm is theoretically analyzed and developed based on buck DC-DC converter loss model and directed towered improving the convergence speed and accuracy of AFO adaptive loop by adjusting the converter switching frequency with variable step size. Finally, the efficiency of DC-DC converters is a function of several variables. Optimizing single variable alone may not result in maximum or global efficiency point. The issue of adjusting more than one variable at the same time is addressed by the Multivariable Adaptive digital Controller (MVAC). The MVAC is an adaptive method that continuously adjusts the DC-DC converter switching frequency and dead-time at the same time, while tracking the converter minimum input power, to find the maximum global efficiency point under variable conditions. In this research work, all adaptive methods were discussed, theoretically analyzed and its digital control algorithm along with experimental implementations were presented.

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Due to unique characteristics, current-mode control architectures with different implementation approaches have been widely used in power converter design to achieve current sharing, AVP control, and light-load efficiency improvement. Therefore, an accurate model for current-mode control is indispensable to system design due to the existence of subharmonic oscillations. The fundamental difference between current-mode control and voltage-mode control is the PWM modulation. The inductor current, one of state variables, is used in the modulator in current-mode control while an external ramp is used in voltage-mode control. The dynamic nonlinearity of current-mode control results in the difficulty of obtaining the small-signal model for current-mode control in the frequency domain. There has been a long history of the current-mode control modeling. Many previous attempts have been made especially for constant-frequency peak current-mode control. However, few models are available for variable-frequency constant on-time control and V2 current-mode control. It's hard to directly extend the model of peak current-mode control to those controls. Furthermore, there is no simple way of modeling the effects of the capacitor ripple which may result in subharmonic oscillations in V2 current-mode control. In this dissertation, the primary objective to investigate a new and general modeling approach for current-mode control with different implementation methods. First, the fundamental limitation of average models for current-mode control is identified. The sideband components are generated and coupled with the fundamental component through the PWM modulator in the current loop. Moreover, the switching frequency harmonics cannot be ignored in the current loop since the current ripple is used for the PWM modulation. Available average models failed to consider the sideband effects and high frequency harmonics. Due to the complexity of the current loop, it is difficult to analyze current loop in the frequency domain. A new modeling approach for current-mode control is proposed based on the time-domain analysis. The inductor, the switches and the PWM modulator are treated as a single entity to model instead of breaking them into parts to do it. Describing function method is used. Proposed approach can be applied not only to constant-frequency modulation but also to variable-frequency modulation. The fundamental difference between different current-mode controls is elaborated based on the models obtained from the new modeling approach. Then, an equivalent circuit representation of current-mode control is presented for the sake of easy understanding. The effect of the current loop is equivalent to controlling the inductor current as a current source with certain impedance. The circuit representation provides both the simplicity of the circuit model and the accuracy of the proposed model. Next, the new modeling approach is extended to V2 current-mode control based on similar concept. The model for V2 current-mode control can accurately predict subharmonic oscillations due to the influence of the capacitor ripple. Two solutions are discussed to solve the instability issue. After that, a digital application of current-mode control is introduced. High-resolution digital pulse-width modulator (DPWM) is considered to be indispensable for minimizing the possibility of unpredicted limit-cycle oscillations, but results in high cost, especially in the application of voltage regulators for microprocessors. In order to solve this issue, a fully digital current-mode control architecture which can effectively limit the oscillation amplitude is presented, thereby greatly reducing the design challenge for digital controllers by eliminating the need for the high-resolution DPWM. The new modeling strategy is also used to model the proposed digital current-mode control to help system design. As a conclusion, a new modeling approach for current-mode control is fully investigated. Describing function method is utilized as a tool in this dissertation. Proposed approach is quite general and not limit by implementation methods. All the modeling results are verified through simulation and experiments. / Ph. D.

Three-phase rectifiers/inverters are widely used in grid-tied applications. Take the electric vehicle (EV) charging systems as an example. Within a certain space designated for the chargers, quick charging yet high efficiency are demanded. According to the current industry practice, with a power rating between 10 and 30 kW, the power density are limited by silicon (Si) power semiconductor devices, which make the systems operate at only up to around 30 kHz. The emerging wide bandgap (WBG) power semiconductor devices are considered as game changing devices to exceed the limits brought by their Si counterparts. Much higher switching frequency, higher power density and higher system efficiency are expected to be achieved with WBG power semiconductor devices. Among different types of WBG power semiconductor devices, Silicon Carbide Metal-Oxide-Semiconductor Field-Effect Transistors (SiC MOSFETs) are more popular in current research conducted for tens of kW power converter applications. However, the commonly adopted hard switching operation in this application still leads to significant switching loss at high frequency operation even for SiC-based systems. With the unique feature that the turn-off energy is almost negligible compared with the turn-on energy, critical conduction mode (CRM) based zero voltage soft switching turn-on operation is preferred for the SiC MOSFETs to eliminate the turn-on loss with small penalty on the conduction loss and on the turn-off loss. With this soft switching operation, switching frequency of SiC-based systems is able to be pushed to more than ten times higher than Si-based systems, and therefore higher power density yet even higher system efficiency can be achieved. The CRM-based soft switching is applied to three-phase rectifiers/inverters under the unity power factor operating condition first. Decoupled CRM-based control is enabled, and the inherent drawback of wide switching frequency variation range at CRM-based operation is overcome by the proposed novel modulation technique. It is the first time that CRM-based soft switching modulation is demonstrated in the most conventional three-phase H-bridge ac–dc converter, and more than three-time size reduction compared with current industry practice yet 99.0% peak efficiency are achieved at above 300 kHz switching frequency operation. Then this proposed soft switching modulation technique is extended to non-unity power factor operating conditions especially for grid-tied inverter system applications. With several improvements on the modulation, a generalized CRM-based soft switching modulation technique is proposed, which is applicable to both the unity and non-unity power factor conditions. With the power factor down to 0.8 lagging or leading according to commercial products, above 98.0% peak efficiency is achieved with the generalized soft switching modulation technique at above 300 kHz switching frequency operation. Furthermore from the aspect of electromagnetic interference (EMI), compared with the traditional Si-based design, CRM operation brings higher differential-mode (DM) EMI noise, and higher dv/dt with SiC MOSFETs brings higher common-mode (CM) EMI noise. What's more, hundreds of kHz switching frequency operation makes the main components of the system EMI spectrum located within the frequency range related to the EMI standard (150 kHz – 30 MHz). Therefore, several methods are adopted for the reduction of EMI noise. The total inductor current ripple is reduced with multi-channel interleaving control in order to reduce DM EMI noise. The balance technique is applied in order to reduce CM EMI noise. With PCB winding coupled inductors, the well-controlled parasitic parameters make the balance technique able to be effective for a uniform reduction of CM EMI noise from 150 kHz to above 20 MHz. In addition, PCB winding based magnetic designs are beneficial to achieving manufacture automation and reducing the labor cost. / Doctor of Philosophy / Power electronics and power conversion are crucial to many applications related to electricity, such as consumer electronics, domestic and commercial appliances, automobiles, data centers, utilities and infrastructure. In today's market, quality and reliability are usually considered as a given; high efficiency (low loss), high power density (small size and weight) and low cost are the main focuses in the design of power electronics products. In the past several decades, significant achievements in power electronics have been witnessed thanks to the silicon (Si) semiconductor technology, especially the Si power semiconductor devices. Nowadays, the development of Si power semiconductor devices is already close to the theoretical limits of the material itself. Therefore, in order to meet the increasing demands from customers in different applications, wide bandgap (WBG) based power semiconductor devices, namely Gallium Nitride (GaN) and Silicon Carbide (SiC), are becoming attractive because of its great potential compared with their Si counterparts. In literature, great contributions have already been made to understanding the WBG based power semiconductor devices. It is exciting and encouraging that some of the GaN-based power electronics products featuring high efficiency, high power density and low cost have been commercialized in consumer electronics applications. However, when pursuing these objectives, previous literature has not shown any applications of high frequency soft switching technology into the high power ac–dc conversion (usually three-phase ac–dc) in a simple way as the low power ac–dc conversion (usually single-phase ac–dc) in consumer electronics products. The key to achieving high efficiency, high power density and low cost is the high frequency soft switching operation. For single-phase ac–dc systems, the research on the realization of soft switching by control strategies instead of additional physical complexity has been intensively conducted, and this technology has also been adopted in the current industry practice. Therefore, the major achievement of this work is the development of a generalized soft switching control strategy for three-phase ac–dc systems, without adding any physical complexity, which is applicable to the simplest and most conventional three-phase ac-dc circuit topology. The proposed soft switching control strategy features bidirectional (rectifiers/inverters) power conversion, active/reactive power transfer, grid-tied/stand-alone modes, and scalability to multi-channel interleaved operation. Furthermore, with high frequency, the integration of magnetic components with embedded windings in the printed circuit board (PCB) becomes feasible, which is also beneficial to achieving electromagnetic compatibility (EMC) and manufacture automation. Based on the proposed control strategy and design methodology, a SiC-based 25-kW three-phase high frequency soft switching rectifier/inverter is developed for various applications such as electric vehicle (EV) charging stations, uninterruptible power supplies (UPS) and renewable energy based utilities.

This thesis focuses on the study, implementation and improvement of a digital Generator Control Unit (GCU) for a high-speed synchronous brushless generator. The control of variable frequency power system, a preferred candidate in More Electric Aircraft (MEA), becomes a big challenge. Compared with conventional analog GCU, digital GCU is a future trend due to the properties such as easy tuning, modification and no aging. Control approaches adopted in the new GCU design is introduced. It has multiloop structure and model-based characteristics. Sensorless rotor position detection was used to finish Park transformation. DSP+FPGA based controller hardware was developed in the lab. A set of hardware was designed to implement the control algorithms. VHDL-based software was developed for FPGA, which is working as a bridge between DSP and peripheral circuits. C-based software was designed to implement control algorithm inside DSP. A testbed system was developed according to the lab capacity of CPES. The complete load transit responses were tested according to the standard ISO1540 and EN8420. Good match between simulation and experiment has been reached. Compared with benchmark controller, great improvement in both steady state and dynamic performance is realized. A feasibility of using digital GCU in the next generation aircraft has been proved preliminarily. However, the challenge of reliability issues in digital system and software still needs further attention. / Master of Science