This dissertation proposes a high-power, high-frequency and high-density three-level parallel resonant converter for capacitor charging. DC-DC pulsed power converters are widely used in military and medical systems, where the power density requirement is often stringent. The primary means for reducing the power converter size has been to reduce loss for reduced cooling systems and to increase the frequency for reduced passive components. Three-level resonant converters, which combine the merits of the three-level structure and resonant converters, are an attractive topology for these applications. The three-level configuration allows for the use of lower-voltage-rating and faster devices, while the resonant converter reduces switching loss and enhances switching capability. This dissertation begins with an analysis of the influence of variations in the structure of the resonant tank on the transformer volume, with the aim of achieving a high power density three-level DC-DC converter. As one of the most bulky and expensive components in the power converter, the different positions of the transformer within the resonant tank cause significant differences in the transformer's volume and the voltage and current stress on the resonant elements. While it does not change the resonant converter design or performance, the improper selection of the resonant tank structure in regard to the transformer will offset the benefits gained by increasing the switching frequency, sometimes even making the power density even worse than the power density when using a low switching frequency. A methodology based on different structural variations is proposed for a high-density design, as well as an optimized charging profile for transformer volume reduction. The optimal charging profile cannot be perfectly achieved by a traditional output-voltage based variable switching frequency control, which either needs excess margin to guarantee ZVS, or delivers maximum power with the danger of losing ZVS. Moreover, it cannot work for widely varied input voltages. The PLL is introduced to overcome these issues. With PLL charging control, the power can be improved by 10% with a narrow frequency range. The three-level structure in particular suffers unbalanced voltage stress in some abnormal conditions, and a fault could easily destroy the system due to minimized margin. Based on thoroughly analysis on the three-level behaviors for unbalanced voltage stress phenomena and fault conditions, a novel protection scheme based on monitoring the flying capacitor voltage is proposed for the three-level structure, as well as solutions to some abnormal conditions for unbalanced voltage stresses. A protection circuit is designed to achieve the protection scheme. A final prototype, built with a custom-packed MOSFET module, a SiC Schottky diode, a nanocrystalline core transformer with an integrated resonant inductor, and a custom-designed oil-cooled mica capacitor, achieves a breakthrough power density of 140W/in3 far beyond the highest-end power density reported (<100 W/in3) in power converter applications. / Ph. D.

Electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs) are gaining popularity because they are more environmentally friendly, less noisy and more efficient. These vehicles have batteries can be charged by on-board battery chargers that can be conductive or inductive. In conductive chargers, the charger is physically connected to the grid by a connector. With the inductive chargers, energy can be transferred wirelessly over a large air-gap through inductive coupling, eliminating the physical connection between the charger and the grid. A typical on-board battery charger consists of a boost power factor correction (PFC) converter followed by a dc-dc converter. This dissertation focuses on the design, modeling and control of a bidirectional dc-dc converter for conductive battery charging application. In this dissertation, a detailed design procedure is presented for a bidirectional CLLLC-type resonant converter for a battery charging application. This converter is similar to an LLC-type resonant converter with an extra inductor and capacitor in the secondary side. Soft-switching can be ensured in all switches without additional snubber or clamp circuitry. Because of soft-switching in all switches, very high-frequency operation is possible, thus the size of the magnetics and the filter capacitors can be made small. To further reduce the size and cost of the converter, a CLLC-type resonant network with fewer magnetics is derived from the original CLLLC-type resonant network. First, an equivalent model for the bidirectional converter is derived for the steady-state analysis. Then, the design methodology is presented for the CLLLC-type resonant converter. Design of this converter includes determining the transformer turns ratio, design of the magnetizing inductance based on ZVS condition, design of the resonant inductances and capacitances. Then, the CLLC-type resonant network is derived from the CLLLC-type resonant network. To validate the proposed design procedure, a 3.5 kW converter was designed following the guidelines in the proposed methodology. A prototype was built and tested in the lab. Experimental results verified the design procedure presented. The dynamics analysis of any converter is necessary to design the control loop. The bandwidth, phase margin and gain margin of the control loops should be properly designed to guarantee a robust system. The dynamic analysis of the resonant converters have not been extensively studied, with the previous work mainly concentrated on the steady-state models. In this dissertation, the continuous-time large-signal model, the steady-state operating point, and the small-signal model are derived in an analytical closed-form. This model includes both the frequency and the phase-shift control. Simulation and experimental verification of the derived models are presented to validate the presented analysis. A detailed controller design methodology is proposed in this dissertation for the bidirectional CLLLC-type resonant converter for battery charging application. The dynamic characteristics of this converter change significantly as the battery charges or discharges. And, at some operating points, there is a high-Q resonant peaking in the open-loop bode-plot for any transfer functions in this converter. So, if the controller is not properly designed, the closed-loop system might become unstable at some operating points. In this paper, a controller design methodology is proposed that will guarantee a stable operation during the entire operating frequency range in both battery charging mode (BCM) and regeneration mode (RM). To validate the proposed controller design methodology, the output current and voltage loop controllers are designed for a 3.5 kW converter. The step response showed a stable system with good transient performance thus validating the proposed controller design methodology. / Ph. D.

The batteries used to power wireless sensor nodes have become a major roadblock for the wide deployment. Harvesting energy from mechanical vibrations using piezoelectric cantilevers provides possible means to recharge the batteries or eliminate them. Raw power harvested from ambient sources should be conditioned and regulated to a desired voltage level before its application to electronic devices. The efficiency and self-powered operation of a power conditioning and management circuit is a key design issue. In this research, we investigate the characteristics of piezoelectric cantilevers and requirements of power conditioning and management circuits. A two-stage conditioning circuit with a rectifier and a DC-DC converter is proposed to match the source impedance dynamically. Several low-power design methods are proposed to reduce power consumption of the circuit including: (i) use of a discontinuous conduction mode (DCM) flyback converter, (ii) constant on-time modulation, and (iii) control of the clock frequency of a microcontroller unit (MCU). The DCM flyback converter behaves as a lossless resistor to match the source impedance for maximum power point tracking (MPPT). The constant on-time modulation lowers the clock frequency of the MCU by more than an order of magnitude, which reduces dynamic power dissipation of the MCU. MPPT is executed by the MCU at intermittent time interval to save power. Experimental results indicate that the proposed system harvests up to 8.4 mW of power under 0.5-g base acceleration using four parallel piezoelectric cantilevers and achieves 72 percent power efficiency. Sources of power losses in the system are analyzed. The diode and the controller (specifically the MCU) are the two major sources for the power loss. In order to further improve the power efficiency, the power conditioning circuit is implemented in a monolithic IC using 0.18-μ­m CMOS process. Synchronous rectifiers instead of diodes are used to reduce the conduction loss. A mixed-signal control circuit is adopted to replace the MCU to realize the MPPT function. Simulation and experimental results verify the DCM operation of the power stage and function of the MPPT circuit. The power consumption of the mixed-signal control circuit is reduced to 16 percent of that of the MCU. / Ph. D.

Solar energy as one type of the renewable energy becomes more and more popular which has led to increase the photovoltaic (PV) installations recently. One of the PV installations is the power conditioning system which is to convert the maximum available power output of the PV modules to the utility grid. Single-phase microinverters are commonly used to integrate the power to utility grid in modular power conditioning system. In the two-stage microinverter, each PV module is connected with a power converter which can transfer higher output power due to the tracking maximum power point (MPP) capability. However, it also has the disadvantages of lower power conversion efficiency due to the increased number of power electronics converters. The primary objective of this thesis is to develop a high-efficiency microconverter to increase the output power capability of the modular power conditioning systems. A topology with hybrid modes of operation are proposed to achieve wide-input regulation while achieving high efficiency. Two operating modes are introduced in details. Under high-input conditions, the converter acts like a buck converter, whereas the converter behaves as a boost converter under low-input conditions. The converter operates as the series resonant converter with normal-input voltage to achieve the highest efficiency. With this topology, the converter can achieve zero-voltage switching (ZVS) and/or zero-current switching (ZCS) of the primary side MOSFETs, ZCS and/or ZVS of the secondary side MOSFETs and ZCS of output diodes under all operational conditions. The experimental results based on a 300 W prototype are given with 98.1% of peak power stage efficiency and 97.6% of weighted California Energy Commission (CEC) efficiency including all auxiliary and control power under the normal-input voltage condition. / Master of Science

With the fast development of information technology (IT) industry, the demand and market volume for off-line power supplies keeps increasing, especially those for desktop, flat-panel TV, telecommunication, computer server and datacenter. An off-line power supply normally consists of electromagnetic interference (EMI) filter, power factor correction (PFC) circuit and isolated DC/DC converter. Isolated DC/DC converter occupies more than half of the volume in an off-line power supply and takes the most control responsibilities, so isolated DC/DC converter is the key aspect to improve the overall performance and reduce the total cost for off-line power supply. On the other hand, of all the power supplies for industrial applications, those for the data center servers are the most performance driven, energy and cost conscious due to the large electricity consumption. The total power consumption of today's data centers is becoming noticeable. Moreover, with the increase in cloud computing and big data, energy use of data centers is expected to continue rapidly increasing in the near future. It is very challenging to design isolated DC/DC converters for datacenters since they are required to provide low-voltage high-current output and fast transient response. The LLC resonant converters have been widely used as the DC-DC converter in off-line power supplies and datacenters due to its high efficiency and hold-up capability. Using LLC converters can minimize switching losses and reduce electromagnetic interference. Almost all the high-end offline power supplies employs LLC converters as the DC/DC converter. But there are three major challenges in LLC converters. Firstly, the control characteristics of the LLC resonant converters are very complex due to the dynamics of the resonant tank. This dissertation proposes to implement a special LLC control method, state-trajectory control, with a low-cost microcontroller (MCU). And further efforts have been made to integrate all the state-trajectory control function into one MCU for high-frequency LLC converters, including start-up and short-circuit protection, fast transient response, light load efficiency improvement and SR driving. Secondly, the transformer in power supplies for IT industry is very bulky and it is very challenging to design. By pushing switching frequency up to MHz with gallium nitride (GaN) devices, the magnetics can be integrated into printed circuit board (PCB) windings. This dissertation proposes a novel matrix transformer structure and its design methodology. On the other hand, shielding technique can be employed to suppress the CM noise for PCB winding transformer. This dissertation proposes a novel shielding technique, which not only suppresses CM noise, but also improves the efficiency. The proposed transformer design and shielding technique is applied to an 800W 400V/12V LLC converter design. Thirdly, the LLC converters have sinusoidal current shape due to the nature of resonance, which has larger root mean square (RMS) of current, as well as larger conduction loss, compared to pulse width modulation (PWM) converter. This dissertation employs three-phase interleaved LLC converters to reduce the circulating energy by inter-connecting the three phases in certain way, and proposed a novel magnetic structure to integrated three inductors and three transformers into one magnetic core. By pushing switching frequency up to 1MHz, all the magnetics can be implemented with 4-layer PCB winding. Additional 2-layer shielding can be integrated to reduce CM noise. The proposed magnetic structure is applied to a 3kW 400V/12V LLC converter. This dissertation solves the challenges in analysis, digital control, magnetic design and EMI in high-frequency DC/DC converters in off-line power supplies. With the academic contribution in this dissertation, GaN devices can be successfully applied to high-frequency DC/DC converters with MHz switching frequency to achieve high efficiency, high power density, simplified but high-performance digital control and automatic manufacturing. The cost will be reduced and the performance will be improved significantly. / Ph. D.

The Class-E topology was presented as a single-switch power amplifier with high efficiency at the optimum condition, where the switch enjoys zero-voltage switching (ZVS) and zero-voltage-derivative switching (ZDS). It is also used in MHz dc-dc converters, and in inverters for wireless power transfer, induction heating, and plasma pulsing. The load current in these applications usually varies over a range. Efficiency of a conventional Class-E design degrades dramatically due to the hard switching beyond the optimum conditions. Keeping ZVS with load change in a Class-E topology is preferred within the load range. Soft switching with load variation is realized by duty cycle modulation with additional transformer, matching network, or resistance compression network. Since two ZVS requirements need to be satisfied in a conventional Class-E design, at least two parameters are tuned under load variation. Thus, changing switching frequency, duty cycle, and component values were used. Impressively, a load-independent Class-E inverter design was presented in 1990 for maintaining ZVS and output voltage under a given load change without tuning any parameters, and it was validated with experimental results recently. The operating principle of this special design (inconsistent with the conventional design) is not elucidated in the published literatures. Load-independency illucidation by a Thevenin Model – A Thevenin model is then established (although Class-E is a nonliear circuit) to explain the load-independency with fixed switching frequency and duty cycle. The input block of a Class-E inverter (Vin, Lin, Cin, and S) behaves as a fixed voltage source vth1 and a fixed capacitive impedance Xth1 in series at switching frequency. When the output block (Lo and Co) is designed to compensate Xth1, the output current phase is always equal to the phase of vth1 with resistive load (satisfies the ZVS requirement of a load-independent design). Thus, soft switching is maintained within load variation. Output voltage is equal to vth1 since Xth1 is canceled, so that the output voltage is constant regardless of output resistance. Load-independency is achieved without adding any components or tuning any parameters. Sequential design and tuning of a load-independent ZVS Class-E inverter with constant voltage based on Thevenin Model - Based on the model, it's found that each circuit parameter is linked to only one of the targeted performance (ZVS, fixed voltage gain, and load range). Thus, the sequential design equations and steps are derived and presented. In each step, the desired performance (e.g. ZVS) now could be used to check and tune component values so that ZVS and fixed voltage gain in the desired load range is guaranteed in the final Class-E inverter, even when component values vary from the expectations. The Thevenin model and the load-independent design is then extended to any duty cycles. A prototype switched at 6.78 MHz with 10-V input, 11.3-V output, and 22.5-W maximum output power was fabricated and tested to validate the theory. Soft switching is maintained with 3% output voltage variation while the output power is reduced tenfold. A load-independent ZVS Class-E inverter with constant current by combining constant voltage design and a trans-susceptance network - A load-independent ZVS Class-E inverter with constant current under load variation is then presented, by combining the presented design (generating a constant voltage) and a trans-susceptance network (transferring the voltage to current). The impact of different types and the positions of the networks are discussed, and LCL network is selected so that both constant current and soft switching are maintained within the load variation. The operation principle, design, and tuning procedures are illustrated. The trade-off between input current ripple, output current amplitude, and the working load range is discussed. The expectations were validated by a design switched at 6.78 MHz with 10-V input, 1.4-A output, and 12.6-W maximum output power. Soft switching is maintained with 16% output current varying over a 10:1 output power range. A "ZVS" Class-E dc-dc converter by adding a diode rectifier bridge and compensate the induced varying capacitance at full-load condition - The load-independent Class-E design is extended to dc-dc converter by adding a diode rectifier bridge followed by the Class-E inverter. The equivalent impedance seen by the inverter consists of a varying capacitance and a varying resistance when the output changes. As illustrated before, ZVS and constant output can only be maintained with resistive load. Since the varying capacitance cannot be compensated for the whole load range, performance with using different compensation is discussed. With the selected full-load compensation, ZVS is achieved at full load condition and slight non-ZVS occurs for the other load conditions. The expectation was validated by a dc-dc converter switched at 6.78 MHz with 11 V input, 12 V output, and 22 W maximum output power. ZVS (including slight non-ZVS) is maintained with 16% output voltage variation over 20:1 output power range. Design of variable Capacitor by connecting two voltage-sensitive capacitors in series and controlling the bias voltage of them - The equivalent varying capacitance in the Class-E dc-dc converter can be compensated in the whole load range only with variable component. The sensitivity of a Class-E power conversion can also be improved by using variable capacitors. Thus, a Voltage Controlled Capacitor (VCC) is presented, based on the intrinsic property of Class II dielectric materials that permittivity changing much with electric field. Its equivalent circuit consists of two identical Class II capacitors in series. By changing the voltage of the common point of the two capacitors (named as control voltage), the two capacitance and the total capacitance are both changed. Its operation principle, measured characteristic, and the SPICE model are illustrated. The capacitance changes from 1 μF to 0.2 μF with a control voltage from 0 V to 25 V, resulting a 440% capacitance range. Since the voltage across the two capacitors (named as output voltage) also affects one of the capacitance when control voltage is applied, the capacitance range drops to only 40% with higher bias in the output voltage. Thus, a Linear Variable Capacitor (LVC) is presented. The equivalent circuit is the same as VCC, while one of the capacitance is designed much higher to mitigate the effect of output voltage. The structure, operational principle, required specifications, design procedures, and component selection were validated by a design example, with 380% maximum capacitance range and less than 20% drop in the designed capacitor voltage range. This work contributes to • Analytical analysis and Thevenin Model in load-independent Class-E power conversion • Variable capacitance with wide range / Doctor of Philosophy / The Class-E topology was presented as a single-switch power amplifier with high efficiency at the optimum condition. Efficiency of a conventional Class-E design degrades with load variation dramatically due to the hard switching beyond the optimum conditions. Since two requirements need to be satisfied for soft switching in a conventional Class-E design, at least two parameters are tuned under load variation. Impressively, a load-independent Class-E inverter design was presented for maintaining Zero-Voltage-Switching (ZVS) and output voltage under a given load change without tuning any parameters, and it was validated with experimental results recently. A Thevenin model is established in this work to explain the realization of load-independency with fixed switching frequency and duty cycle. Based on that, a sequential design and tuning process is presented. A prototype switched at 6.78 MHz with 10-V input, 11.3-V output, and 22.5-W maximum output power was fabricated and tested to validate the theory. Soft switching is maintained with 3% output voltage variation while the output power is reduced tenfold. A load-independent ZVS Class-E inverter with constant current under load variation is then presented, by combining the presented design and a trans-susceptance network. The expectations were validated by a design switched at 6.78 MHz with 10-V input, 1.4-A output, and 12.6-W maximum output power. Soft switching is maintained with 16% output current varying over a 10:1 output power range. The load-independent Class-E design is extended to dc-dc converter by adding a diode rectifier bridge, inducing a varying capacitance. With the selected full-load compensation, ZVS is achieved at full load condition and slight non-ZVS occurs for the other load conditions. The expectation was validated by a dc-dc converter switched at 6.78 MHz with 11 V input, 12 V output, and 22 W maximum output power. ZVS (including slight non-ZVS) is maintained with 16% output voltage variation over 20:1 output power range. The varying capacitance in the Class-E dc-dc converter needs variable component to compensate. Thus, a Voltage Controlled Capacitor (VCC) is presented. The capacitance changes from 1 μF to 0.2 μF with a control voltage from 0 V to 25 V, resulting a 440% capacitance range. The capacitance range drops to only 40% with higher bias in the output voltage. Thus, a Linear Variable Capacitor (LVC) is presented, with 380% maximum capacitance range and less than 20% drop in the designed capacitor voltage range.

The popularity of the internal combustion engine (ICE) vehicles has contributed to global warming problem and degradation of air quality around the world. Furthermore, the vehicles??? massive demand on gas has played a role in the depletion of fossil fuel reserves and the considerable rise in the gas price over the past twenty years. Those existing challenges force the auto-industry to move towards the technology development of vehicle electrification. An electrified vehicle is driven by one or more electric motors. And the electricity comes from the onboard energy storage system (ESS). Currently, no single type of green energy source could meet all the requirements to drive a vehicle. A hybrid energy storage system (HESS), as a combination of battery and ultra-capacitor units, is expected to improve the overall performance of vehicles??? ESS. This thesis focuses on the design of HESS and the development of a HESS prototype for electric vehicles (EVs) and hybrid electric vehicles (HEVs). Battery unit (BU), ultra-capacitor unit (UC) and a DC/DC converter interfacing BU and UC are the three main components of HESS. The research work first reviews literatures regarding characteristics of BU, UC and power electronic converters. HESS design is then conducted based on the considerations of power capability, energy efficiency, size and cost optimization. Besides theoretical analysis, a HESS prototype is developed to prove the principles of operation as well. The results from experiment are compared with those from simulation.

This thesis studies a multiple-input single ended primary inductor converter (MI SEPIC) topology. The configuration allows the integration of different low-power distributed generation sources, such as individual photovoltaic modules, fuel cells, and small residential wind generators, into a common dc main bus. The current source interface allows the integration of all types of sources without the addition of filters; sources that require a nearly constant input current, such as fuel cells. In addition to discussing the circuit’s main models and operation, the thesis evaluates the stability under a decentralized PI control scheme through small signal analysis. The analysis is verified with simulations and experiments with prototypes. A derived circuit topology, the isolated MI SEPIC, is also explored here. In addition, a nonlinear control scheme, Lyapunov-based control, is implemented to stabilize an MI SEPIC. / text

Thesis (M. Tech. Engineering: Electrical)--Vaal University of Technology / Fuel cells are electrochemical devices that convert chemical energy of a fuel cell into electricity at high efficiency without combustion. They are viewed as viable power sources for many applications including automobiles, distributed power generation and portable electronics. This dissertation presents the design and development of a phosphoric acid fuel cell. It deals with the experimental studies on phosphoric acid fuel cells and possible integration in replacing the conventional sources of electrical energy in stand-by power supply systems, particularly for use in the telecommunications industry. The design of a DC-DC converter system is also incorporated into the system. The first objective was to establish performance parameters and past studies on phosphoric acid fuel cells and this research revealed that parameters that affect the system's performance include: reactant gas pressures, mass flow rates as well as the operating temperature. Mathematical models in the literature were studied and verified against the simulation models acquired. The second objective was to design and assemble a single cell in order to analyze the cell's performances as well as the operating parameters in order to obtain a model for predicting and simulating the performance of larger fuel cell stacks. The next objective was to analyse from a set of design equations and construct a small DC-DC converter. The converter was used to boost a small fuel cell voltage and regulate it at a higher voltage level. Finally, the performance characteristics of the developed fuel cell, mathematical and simulation models were evaluated and compared. Simulation results for the models and the converter showing a regulated output voltage are presented. Some recommendations for improved system performance and for further studies are suggested.

Esta dissertação aborda aspectos gerais relativos à utilização de um conversor CC-CC que opera conectado à rede de distribuição e que emprega como fonte primária células a combustível. Neste trabalho, a modelagem matemática em espaços de estados (pequenos sinais e média) dos conversores Boost e Boost Interleaved com Multiplicador de Tensão (IBVM), assim como as arquiteturas de controle utilizadas em modo tensão, corrente média e corrente de pico são comparadas para determinar qual delas apresenta melhor desempenho. Devido ao fato das células a combustível apresentarem tensão terminal baixa e corrente terminal elevada, há a necessidade de utilizar conversores eletrônicos com alto ganho para equalizar a tensão produzida pela fonte com o nível de tensão presente na rede de distribuição. Tendo isso em vista, este trabalho mostra uma análise do ganho estático de tensão do conversor Boost e IBVM considerando os efeitos das resistências parasitas dos componentes utilizados e da carga conectada nos terminais de saída do conversor. Como resultado da modelagem matemática do ganho, é mostrado um conjunto de equações que definem o valor mínimo de resistência do semicondutor de potência, indutor, capacitor do multiplicador de tensão e a máxima carga que os conversores Boost e Boost Interleaved com Multiplicador de Tensão podem suprir. Por fim, os resultados experimentais são apresentados com o intuito de validar os resultados teóricos e de simulação obtidos. / This thesis addresses general aspects concerning the application of DC-DC converters applied to a grid connected Fuel Cell system. It is discussed in this thesis the averaged and small signals space state modeling of the Boost and Interleaved Boost with Voltage Multiplier (IBVM) converter, it is also mentioned the control architectures in voltage mode, average current mode and peak current mode. The voltage and average current mode control architectures are simulated and implemented in hardware in order to be compared. Due to the fact that Fuel Cells present low terminal voltage and high current, it is needed to use high gain DC-DC converters with the aim connect the system to the grid. This thesis also presents an approach in the analysis of DC-DC converter static voltage gain considering the effect of the parasitic resistances and the load connected to the converter terminals. As a result of the gain analysis, it is presented a set of equation, from which is possible to determine the maximum value of the parasitic resistances for the switch, inductor and capacitor of the voltage multiplier. It is also calculated the maximum value of load connected to the Boost and Interleaved Boost with Voltage Multiplier converters with the aim to present the designed voltage gain. Additionally, by the maximum load value calculated it is possible to determine the maximum power that the converter will be capable to process, considering a specific point of operation. Finally, the designed DC-DC converter is implemented with the aim to validate the theoretical and simulation results.