With the increased interest in applying Power Factor Correction (PFC) to off-line AC-DC converters, the field of integrated, single-stage PFC converter development has attracted wide attention. Considering the tens of millions of low-to-medium power supplies manufactured each year for today's rechargeable equipment, the expected reduction in cost by utilizing advanced technologies is significant. To date, only a few single-stage topologies have made it to the market due to the inherit limitations in this structure. The high voltage and current stresses on the components led to reduced efficiency and an increased failure rate. In addition, the component prices tend to increase with increased electrical and thermal requirements, jeopardizing the overarching goal of price reduction. The absence of dedicated control circuitry for each stage complicates the power balance in these converters, often resulting in an oversized bus capacitance. These factors have impeded widespread acceptance of these new techniques by manufacturers, and as such single stage PFC has remained largely a drawing board concept. This dissertation will present an in-depth study of innovative solutions that address these problems directly, rather than proposing more topologies with the same type of issues. The direct energy transfer concept is analyzed and presented as a promising solution for the majority of the single-stage PFC converter limitations. Three topologies are presented and analyzed based on this innovative structure. To complete the picture, the dynamics of a variety of single-stage converters can be analyzed using a proposed switched transformer model.

Evolutions in integrated circuit technology require the use of a high-frequency synchronous buck converter in order to achieve low cost, low profile, fast transient response and high power density. However, high frequency operation leads to increased power MOSFET switching losses. Optimization of the MOSFETs plays an important role in improving converter performance. This dissertation focuses on revealing the power loss mechanism of power MOSFETs and the relationship between power MOSFET structure and its power loss. The analytical device model, combined with circuit modeling, cannot reveal the relationship between device structure and its power loss due to the highly non-linear characteristics of power MOSFETs. A physically-based mixed device/circuit modeling approach is used to investigate the power losses of the MOSFETs under different operating conditions. The physically based device model, combined with SPICE-like circuit simulation, provides an expeditious and inexpensive way of evaluating and optimizing circuit and device concepts. Unlike analytical or other SPICE models of power MOSFETs, the numerical device model, relying little on approximations or simplifications, faithfully represents the behavior of realistic power MOSFETs. The impact of power MOSFET parameters on efficiency of synchronous buck converters, such as gate charge, on resistance, reverse recovery, is studied in detail in this thesis. The results provide a good indication on how to optimize power MOSFETs used in VRMs. The synchronous rectifier plays an important role in determining the performance of the synchronous buck converter. The reverse recovery of its body diode and the Cdv/dt induced false trigger-on are two major mechanisms that impact SyncFET's performance. This thesis gives a detailed analysis of the SyncFET operation mechanism and provides several techniques to reduce its body-diode influence and suppress its false Cdv/dt trigger-n. This thesis also investigates the influence of several circuit level parameters on the efficiency of the synchronous buck converter, such as input voltage, circuit parasitic inductance, and gate resistance to provide further optimization of synchronous buck converter design.

Renewable energy source plays an important role in energy co-generation and distribution. A traditional solar-based inverter system has two stages cascaded, which has simpler controller but low efficiency. A new solar-based single-stage grid-connected inverter system can achieve higher efficiency by reducing the power semiconductor switching loss and output stable and synchronizing sinusoid current into the utility grid. In Chapter 1, the characteristic I-V and P-V curve of PV array has been illustrated. Based on prediction of the PV power capacity installed on the grid-connected and off-grid, the trends of grid-tied inverter for DG system have been analyzed. In Chapter 2, the topologies of single-phase grid-connect inverter system have been listed and compared. The key parameters of all these topologies are listed in a table in terms of topology, power decoupling, isolation, bi-directional/uni-directional, power rating, switching frequency, efficiency and input voltage. In Chapter 3, to reduce the capacitance of input filter, an active filter has been proposed, which will eliminate the 120/100Hz low frequency ripple from the PV array's output voltage completely. A feedforward controller is proposed to optimize the step response of PV array output voltage. A sample and hold also is used to provide the 120/100Hz low frequency decoupling between the controller of active filter and inverter stage. In Chapter 4, the single-stage inverter is proposed. Compared with conventional two-stage inverter, which has two high frequency switching stages cascaded, the single-stage inverter system increases the system efficiency by utilizing DC/DC converter to generate rectified sinusoid voltage. A transformer analysis is conducted for the single-stage inverter system, which proves the transformer has no low-frequency magnetic flux bias. To apply peak current mode control on single-stage inverter and get unified loop gain, adaptive slope compensation is also proposed for single-stage inverter. In Chapter 5, a digital controller for single-stage inverter is designed and optimized by the Matlab Control Toolbox. A Psim simulation verified the performance of the digital controller design. In Chapter 6, three bi-directional single-stage inverter topologies are proposed and compared. A conventional single-stage bi-directional inverter has certain shortcoming that cannot be overcome. A modular grid-connect micro-inverter system with dedicated reactive energy processing unit can overcome certain shortcoming and increase the system efficiency and reliability. A unique controller design is also proposed. In Chapter 7, a PFM ZCS flyback inverter system is invented. By using half-wave quasi-resonant ZCS flyback resonant converter and PFM control, this topology completely eliminates switching loss. A detailed mathematical analysis provides all the key parameters for the inverter design. As the inductance of transformer secondary side get smaller, the power stage transfer function of PFM ZCS flyback inverter system demonstrates nonlinearity. An optimized PFM ZCS flyback DC/DC converter design resolves this issue by introducing a MOSFET on the secondary side of transformer. In Chapter 8, experimental results of uni-direcitonal single-stage inverter with grid-connection, bi-directional single-stage inverter and single-stage PFM ZCS flyback inverter have been provided. Conclusions are given in Chapter 9.

A monolithically integrated smart rectifier has been presented first in this work. The smart rectifier, which integrates a power MOSFET, gate driver and control circuitry, operates in a self-synchronized fashion based on its drain-source voltage, and does not need external control input. The analysis, simulation, and design considerations are described in detail. A 5V, 5-µm CMOS process was used to fabricate the prototype. Experimental results show that the proposed rectifier functions as expected in the design. Since no dead-time control needs to be used to switch the sync-FET and ctrl-FET, it is expected that the body diode losses can be reduced substantially, compared to the conventional synchronous rectifier. The proposed self-synchronized rectifier (SSR) can be operated at high frequencies and maintains high efficiency over a wide load range. As an example of the smart rectifier's application in isolated DC-DC converter, a synchronous flyback converter with SSR is analyzed, designed and tested. Experimental results show that the operating frequency could be as high as 4MHz and the efficiency could be improved by more than 10% compared to that when a hyper fast diode rectifier is used. Based on a new current-source gate driver scheme, an integrated gate driver for buck converter is also developed in this work by using a 0.35µm CMOS process with optional high voltage (50V) power MOSFET. The integrated gate driver consists both the current-source driver for high-side power MOSFET and low-power driver for low-side power iv MOSFET. Compared with the conventional gate driver circuit, the current-source gate driver can recovery some gate charging energy and reduce switching loss. So the current-source driver (CSD) can be used to improve the efficiency performance in high frequency power converters. This work also presents a new implementation of a power supply in package (PSiP) 5MHz buck converter, which is different from all the prior-of-art PSiP solutions by using a high-Q bondwire inductor. The high-Q bondwire inductor can be manufactured by applying ferrite epoxy to the common bondwire during standard IC packaging process, so the new implementation of PSiP is expected to be a cost-effective way of power supply integration.

No description available.

Battery energy storage system (BESS) is promising to be implemented in residential applications for supporting PV integration, load shifting, and backup power purposes. For this application, 48V second-life battery draws more and more attentions for their cost-effectiveness, safe voltage level, reliability, and potential large market. This thesis proposes the comprehensive control and design of an isolated battery-driven grid interface (IBDGI) with the dual-active-bridge (DAB) converter for residential applications with 48V battery pack. The three-phase DAB converter is a promising candidate as the front-end DC/DC converter in the two-stage IBDGI due to its high efficiency, high power density, and low capacitance requirement. An effective design strategy for the three-phase DAB converter is proposed based on the zero-voltage-switching (ZVS) zone and back-ow power to achieve high efficiency for a wide operating voltage range and different load conditions. Based on the power loss model, an easily-implemented variable switching frequency operating method is proposed to further increase the efficiency at light load conditions. The dead-time effect is observed in the three-phase DAB converter. To avoid the dead-time effect and better understand the phenomena, a comprehensive analysis is proposed. All the cases of the dead-time effect in the three-phase DAB converter are analyzed in terms of the buck, boost, and matching states. The expressions of the transmission power, constraint conditions, and key time of the dead-time effect are derived for each state. The operation waveforms of the dead-time effect are also presented. The hybrid capacitor bank composed by the LC resonant lter with electrolytic capacitor and lm capacitor is utilized for the DC bus of the IBGDI. The electrolytic capacitors work as passive decoupling purpose while the lm capacitor is responsible for high switching harmonic ltering. Moreover, a current sharing method between the hybrid capacitor bank is proposed to extend the electrolytic capacitor's life. The LCL single-phase inverter is applied for the downstream of the IBDGI. A step-by-step design procedure of the LCL lter with passive damping is proposed for the 120V/240V dual grid-tied and standalone modes. The PR controllers are also designed for the LCL inverter for standalone and grid-tied modes. At the system level, a novel second harmonic current (SHC) reduction strategy is proposed for the IBDGI with the three-phase DAB converter by adding a load current feedforward (LCFF) path to the DAB voltage closed-loop controller. This method will suppress the SHC without modi cations of the original controller's bandwidth, which make it easy to be implemented. The small-signal model of the three-phase DAB converter is provided and veri ed by the step response. The parameter sensitivity analysis for the LCFF method is proposed to show that the SHC is well suppressed within ±20% parameter error. The proposed converter and control methods are veri ed by simulation and experimental results. / Thesis / Doctor of Philosophy (PhD)

Lithium-ion based battery energy storage system has become one of the most popular forms of energy storage system for its high charge and discharge efficiency and high energy density. This dissertation proposes a high-efficiency grid-tie lithium-ion battery based energy storage system, which consists of a LiFePO4 battery based energy storage and associated battery management system (BMS), a high-efficiency bidirectional ac-dc converter and the central control unit which controls the operation mode and grid interface of the energy storage system. The BMS estimates the state of charge (SOC) and state of health (SOH) of each battery cell in the pack and applies active charge equalization to balance the charge of all the cells in the pack. The bidirectional ac-dc converter works as the interface between the battery pack and the ac grid, which needs to meet the requirements of bidirectional power flow capability and to ensure high power factor and low THD as well as to regulate the dc side power regulation. A highly efficient dual-buck converter based bidirectional ac-dc converter is proposed. The implemented converter efficiency peaks at 97.8% at 50-kHz switching frequency for both rectifier and inverter modes. To better utilize the dc bus voltage and eliminate the two dc bus bulk capacitors in the conventional dual-buck converter, a novel bidirectional ac-dc converter is proposed by replacing the capacitor leg of the dual-buck converter based single-phase bidirectional ac-dc converter with a half-bridge switch leg. Based on the single-phase bidirectional ac-dc converter topology, three novel three-phase bidirectional ac-dc converter topologies are proposed. In order to control the bidirectional power flow and at the same time stabilize the system in mode transition, an admittance compensator along with a quasi-proportional-resonant (QPR) controller is adopted to allow smooth startup and elimination of the steady-state error over the entire load range. The proposed QPR controller is designed and implemented with a digital controller. The entire system has been simulated in both PSIM and Simulink and verified with hardware experiments. Small transient currents are observed with the power transferred from rectifier mode to inverter mode at peak current point and also from inverter mode to rectifier mode at peak current point. The designed BMS monitors and reports all battery cells parameters in the pack and estimates the SOC of each battery cell by using the Coulomb counting plus an accurate open-circuit voltage model. The SOC information is then used to control the isolated bidirectional dc-dc converter based active cell balancing circuits to mitigate the mismatch among the series connected cells. Using the proposed SOC balancing technique, the entire battery storage system has demonstrated more capacity than the system without SOC balancing. / Ph. D.

Rapid expansion of the information technology (IT) sector, market size and consumer interest for off-line power supply continue to rise, particularly for computers, flat-panel TVs, servers, telecom, and datacenter applications. Normal components of an off-line power supply include an electromagnetic interference (EMI) filter, a power factor correction (PFC) circuit, and an isolated DC-DC converter. For off-line power supply, an isolated DC-DC converter offers isolation and output voltage adjustment. For an off-line power supply, it takes up significantly more room than the rest; thus, an isolated DC-DC converter is essential for enhancing the overall performance and lowering the total cost of an off-line power supply. In contrast, data center server power supplies are the most performance-driven, energy-efficient, and cost-aware of any industrial application power supply. The full extent of data centers' energy consumption is coming into focus. By 2030, it is anticipated that data centers will require around 30,000 TWh, or 7.6% of world power usage. In addition, with the rise of cloud computing and big data, the energy consumption of data centers is anticipated to continue rising rapidly in the near future. In data centers, isolated DC-DC converters are expected to supply even higher power levels without expanding their size and with much greater efficiency than the present standard, which makes their design even more challenging. LLC resonant converters are frequently utilized as DC-DC converters in off-line power supply and data centers because of their high efficiency and hold-up capabilities. LLC converters may reduce electromagnetic interference because the primary switches and secondary synchronous rectifiers (SRs) both feature zero-voltage-switching (ZVS) and zero-current-switching (ZCS) for the SRs. Almost every state-of-the-art off-line power supply uses LLC converters in their DC-DC transformations. However, LLC converters face three important challenges. First, the excessive core loss caused by the uneven flux distribution in planar magnetics, owing to the huge size and high-frequency operation of the core. These factors led to the observation of dimensional resonance within the core and an excessive amount of eddy current circulating within the core, which resulted in the generation of high eddy loss within the ferrite material. This was normally assumed to be negligible for small core sizes and lower frequencies. This dissertation proposes methods to help redistribute the flux in the core, particularly in the plates where the majority of core losses are concentrated, and to provide more paths for the flux to flow so that the plates' thickness can effectively be reduced by half and core losses, particularly eddy loss, are reduced significantly. Second, the majority of power supplies in the IT sector are needed to deliver high-current output, but the transformer is cumbersome and difficult to build because of its high conduction losses. In addition, establishing a modular solution that can be scaled up to greater power levels while attaining a superior performance relative to best practices is quite difficult. By increasing the switching frequency to several hundred kilohertz using wide-band-gap (WBG) transistors, printed circuit board (PCB) windings may include magnetics. This dissertation offers a modular and scalable matrix transformer structure and its design technique, allowing any number of elemental transformers to be integrated into a single magnetic core with significantly reduced winding loss and core loss. It has been shown that the ideal power limitations per transformer for PCB-based magnetics beat the typical litz wire design in all design areas, in addition to the unique advantages of PCB-magnetics, such as their low profile, high density, simplicity, and automated construction. Alternatively, shielding layers may be automatically put into the PCB windings between the main and secondary windings during the production process to reduce CM noise. A method of shielding is presented to reduce CM noise. The suggested transformer design and shielding method are used in the construction of a 3 kW 400V/48 V LLC converter, with a maximum efficiency of 99.06% and power density of 530W/in3. Thirdly, LLC converters with a matrix transformer encounter a hurdle for extending greater power, including the number of transformers needed and the magnetic size. In addition to the necessity of resonant inductors, which increase the complexity and size of the magnetic structure, there is a need for a resonant inductor. By interconnecting the three-phases in a certain manner, three-phase interleaved LLC converters may lower the circulating energy, but they have large and numerous magnetic components. In this dissertation, a new topology for three-phase LLC resonant converters is proposed. Three-phase systems have the advantage of flux cancellation, which may be used to further simplify the magnetic structure and decrease core loss. In addition, a study of the various three-phase topologies is offered, and a criterion for selecting the best suitable topology is shown. Compared to the single-phase LLC, the suggested topology has less winding loss and core loss. In addition, three-phase transformers have a lower volt-second rating, and smaller core sizes may be used to mitigate the impact of eddy loss in the ferrite material. In contrast, three-phase systems offer superior EMI performance, which is shown in the loss and size of the EMI filter, and much less output voltage ripple, which is reflected in the size of the output filter. Finally, several methods of integrating resonant inductors into transformer magnetics are presented in order to accomplish a simple, compact, and cost-effective magnetic architecture. By increasing the switching frequency to 500 kHz, all six transformers and six inductors may be achieved using four-layer PCB winding. To decrease CM noise, additional 2-layer shielding may be implemented. A 500 kHz, 6-8 kW, 400V/48V, three-phase LLC converter with the suggested magnetic structure achieves 99.1% maximum efficiency and a power density of 1000 W/in3. This dissertation addresses the issues of analysis, magnetic design, expansion to higher power levels, and electromagnetic interference (EMI) in high-frequency DC/DC converters used in off-line power supply and data centers. WBG devices may be effectively used to enable high-frequency DC/DC converters with a hundred kilohertz switching frequency to achieve high efficiency, high power density, simple yet high-performance, and automated manufacture. Costs will be minimized, and performance will be considerably enhanced. / Doctor of Philosophy / The IT industry, market size, and customer interest in off-line power supply continue to grow quickly, especially for computers, flat-panel TVs, servers, telecom, and datacenter applications. Off-line power supplies usually have a DC-DC converter, an EMI filter, and a PFC circuit. A DC-DC converter is needed for an off-line power supply. An isolated DC-DC converter makes an off-line power supply work better and cost less, even though it takes up more space than the rest. But power supplies for data center servers are the most performance-driven, energy-efficient, and cost-conscious industrial applications. It's becoming clear how much energy data centers use. By 2030, data centers will use 7.6% of the world's power, or 30,000 TWh. With the rise of cloud computing and big data, energy use in data centers is likely to go up by a lot. In data centers, isolated DC-DC converters are expected to have much more power without getting bigger and to be much more efficient than the current standard. This makes their design even harder. LLC resonant converters are often used as DC-DC converters in data centers and off-line power supplies because they are very efficient and easy to control. LLC converters may have less electromagnetic interference because both the primary switches and the secondary synchronous rectifiers (SRs) have zero-voltage-switching (ZVS) and zero-current-switching (ZCS). Almost every modern off-line power supply uses LLC converters for DC-DC stage. LLC converters have to deal with three big problems. Due to the large size of the core and the high frequency of operation, the uneven distribution of flux in planar magnetics causes too much core loss. This dissertation suggests ways to redistribute flux in the core, especially in the plates where most core losses are concentrated and provide more flux paths to reduce plate thickness by half and core losses, especially eddy loss. Second, most IT power supplies need to put out a lot of current, but transformers are bulky and hard to build because they lose a lot of current. It is hard to make a modular solution that can scale up to higher levels of power and perform better than best practices. With wide-band-gap (WBG) transistors, the switching frequency can be raised to several hundred kilohertz so that magnetics can be added to PCB windings. This dissertation describes a modular and scalable matrix transformer structure and design method that lets any number of elemental transformers be put into a single magnetic core with much less winding loss and core loss. PCB-based magnetics have a low profile, a high density, are easy to build, and can be built automatically. Their ideal power limits per transformer beat the typical litz wire design in every way. Shielding layers can be added automatically between the main and secondary PCB windings to cut down on CM noise. CM noise is lessened by shielding. The suggested transformer design and shielding method are used to build a 3 kW 400V/48 V LLC converter with a maximum efficiency of 99.06% and a power density of 530W/in3. Third, LLC converters with matrix transformers can't get more power without more transformers and a bigger magnetic size. Resonant inductors, which add to the size and complexity of a magnetic structure, are also needed. By connecting the three phases, three-phase interleaved LLC converters use less energy, but they have a lot of magnetic parts. In this paper, a three-phase LLC resonant converter topology is proposed. In three-phase systems, flux cancellation makes magnetic structures easier to understand and reduces core loss. There is also a study of three-phase topologies and a set of criteria for choosing one. Compared to the single-phase LLC, the topology cuts down on winding and core loss. Three-phase transformers have a lower volt-second rating, and ferrite material eddy loss can be reduced by making the core smaller. The size and loss of the EMI filter show that three-phase systems have less output voltage ripple and better EMI performance. Finally, several ways of putting resonant inductors into the magnetics of a transformer are shown to make a magnetic architecture that is simple, small, and cheap. At 500 kHz, all six transformers and all six inductors can be wound on a four-layer PCB. CM noise can be cut down with 2-layer shielding. With the suggested magnetic structure, a 500 kHz, 6-8 kW, 400V/48V, three-phase LLC converter can reach 99.1% maximum efficiency and 1000 W/in3. This dissertation presents analysis, magnetic design, expanding to higher power levels, and electromagnetic interference (EMI) in high-frequency DC/DC converters used in off-line power supplies and data centers. WBG devices can be used to make high-frequency DC/DC converters with a switching frequency of a few hundred kilohertz that are powerful, easy to use, and can be automated. Both cost and performance will get better.

The battery charger plays an important role in the development of electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs).This thesis focuses on the DC-DC converter for high voltage battery charger and is divided into four chapters. The background related to EV battery charger is introduced, and the topologies of isolated DC-DC converter possibly applied in battery charge are sketched in Chapter 1. Since the EV battery charger is high voltage high power, the phase-shifted full bridge and LLC converters, which are popularly used in high power applications, are discussed in detail in Chapter 2. They are generally considered as high efficiency, high power density and high reliability, but their prominent features are also limited in certain range of operation. To make full use of the advantages and to avoid the limitation of the phase-shifted full bridge and LLC converters, a novel hybrid resonant and PWM converter combining resonant LLC half-bridge and phase shifted full-bridge topology is proposed and is described in Chapter 3. The converter achieves high efficiency and true soft switching for the entire operation range, which is very important for high voltage EV battery charger application. A 3.4 kW hardware prototype has been designed, implemented and tested to verify that the proposed hybrid converter truly avoids the disadvantages of LLC and phase-shifted full bridge converters while maintaining their advantages. In this proposed hybrid converter, the utilization efficiency of the auxiliary transformer is not that ideal. When the duty cycle is large, LLC converter charges one of the capacitors but the energy stored in the capacitor has no chance to be transferred to the output, resulting in the low utilization efficiency of the auxiliary transformer. To utilize the auxiliary transformer fully while keeping all the prominent features of the previous hybrid converter in Chapter 3, an improved hybrid resonant and PWM converter is proposed in Chapter 4. The idea has been verified with simulations. The last chapter is the conclusion which summaries the key features and findings of the two proposed hybrid converters. / Master of Science

<p dir="ltr">The demand for renewable energy and electric vehicles (EVs) is increasing, necessitating efficient energy conversion and management solutions. The thesis addresses the critical challenge of dynamically converting multiple Direct Current (DC) inputs to multiple DC outputs while maintaining efficiency and scalability. The primary objective is to design and test a Multi Input Multi Output (MIMO) DC converter, focusing on verifying its scalability and load efficiency. The research investigates hardware requirements, the implementation of multiphase circuits, and the balancing of power between various inputs through multistage cycling. The study hypothesizes that multistage cycling balances the output power between inputs, and multiphase configurations can scale the converter without affecting efficiency. Methods include examining existing converters, simulating multistage circuits, and fabricating a prototype. Key deliverables include a working prototype demonstrating scalability and efficiency. Results indicate that the MIMO DC converter performs efficiently with multiple inputs and outputs, achieving over 90% efficiency. The use of Gallium Nitride (GaN) transistors and synchronous buck converter topology proves effective in minimizing losses and enhancing stability. The research holds significant value in advancing renewable energy and DC converter technology, promoting sustainability and efficient energy management. Future work should explore advanced filtration circuits, higher voltage testing, and more complex configurations to further enhance the converter's capabilities.</p>