This paper presents the development and study of multiple-input single-output converter (MISO) for the DC House project that utilizes a controller to maximize the overall converter’s efficiency. The premise of this thesis is to create uneven load current sharing between the converters at different loading conditions in order to maximize the efficiency of the overall MISO converter. The goal is to find a proper ratio of current from each converter to the total load current of the MISO system to achieve the greatest efficiency. The Arduino microcontroller is implemented to achieve this goal. The design and operation of the MISO converter with the proposed controller will be explained in this paper. The design and operation of the converter was tested and verified through simulation in LTSpice in addition to hardware implementation. Different ratios of current from each converter were used to fully test the MISO converter. For the 5A and 6A load current, the maximum efficiencies were reached with the 70% / 30% ratio case, with efficiencies of 94.91% and 95.07%, respectively. For 7A load current, the maximum efficiency was reached with the 60% / 40% ratio case, with an efficiency of 94.59%. The results were then compared with those obtained from the equal current sharing cases. For the cases tested, the efficiency of the unequal current sharing outperforms that obtained from the equal current sharing method.

This report details the design and implementation of a switching DC-DC converter for use in the Energy Harvesting From Exercise Machines (EHFEM) project. It uses a four-switch, buck-boost topology to regulate the wide, 5-60 V output of an elliptical machine to 36 V, suitable as input for a microinverter to reclaim the energy for the electrical grid. Successful implementation reduces heat emissions from electrical energy originally wasted as heat, and facilitates a financial and environmental benefit from reduced net energy consumption.

This thesis entails the stability analysis of the Multiple Input Single Output (MISO) DC-DC converter developed for the DC House Project at Cal Poly. A frequency domain control system model of the MISO converter was designed and constructed using MATLAB Simulink. Transfer functions were derived and modeled for each stage of the converter to best fit the converter circuit system used in the original MISO circuit. Stability metrics such as overshoot, undershoot, rise time, phase margin and gain margin were measured to evaluate and analyze the stability of the converter. These metrics were measured with the original model including the current sharing network that allows load sharing between multiple MISO modules. The simulation results demonstrate that based on the existing model, the system is stable with a gain margin of infinity and phase margin of around 40 degrees at crossover frequency of 47kHz with nominal input voltage of 24V. Another compensator was proposed to overcome the shortcomings of the original compensator model with respect to the overshoot and phase margin. The new compensator model improved the phase margin at the same crossover frequency with a higher rise time and lowered percent overshoot. Additional improvements and tradeoffs are further discussed to help with the decision when designing a compensator for DC-DC converter that uses the current mode control technique.

This project proposes a new hybrid voltage divider DC-DC converter that utilizes switching capacitors and inductors to produce zero voltage switching (ZVS) at the turn on state of its switches. By achieving ZVS, the switching losses are significantly reduced; thus, increasing the overall efficiency of the converter at various loads. The goal for this thesis is to perform analysis of the operation of the converter, derive equations for sizing the main components, and demonstrate its functionality through computer simulation and hardware prototype. Results of the simulation and hardware testing show that the proposed converter produces the desired output voltage while providing the zero voltage switching benefits. The converter’s efficiency reaches above 92% starting from 1A load and continues to increase to 97.6% at 4A load. Overall, results from this thesis verifies the potential of the proposed converter as an alternative solution to achieve a very efficient DC-DC solution when half of the input voltage is required at the output without the use of complex feedback control circuitry.

This thesis presents the design, simulation, and hardware implementation of a proposed method for improving efficiency of voltage regulator. Typically, voltage regulator used for noise-sensitive and low-power applications involves the use of a linear regulator due to its high power-supply rejection ratio properties. However, the efficiency of a linear regulator depends heavily on the difference between its input voltage and output voltage. A larger voltage difference across the linear regulator results in higher losses. Therefore, reducing the voltage difference is the key in increasing regulator’s efficiency. In this thesis, a pre switching regulator stage with positive voltage tracking cascaded to a linear regulator is proposed to provide an input voltage to a linear regulator that is slightly above the output of the linear regulator. The tracking capability is needed to provide the flexibility in having different positive output voltage levels while maintaining high overall regulator’s efficiency. Results from simulation and hardware implementation of the proposed system showed efficiency improvement of up to 23% in cases where an adjustable output voltage is necessary. Load regulation performance of the proposed method was also overall better compared to the case without the output voltage tracking method.

High voltage power supply design presents unique requirements, combining safety, controllability, high performance, and high efficiencies. A new Resonant Self-Tracking Current-Fed Converter (RST-CFC) is investigated as a proof-of-concept of a high voltage power supply particularly for an X-ray system. These systems require fast voltage rise times and low ripple to yield a clear image. The proposed converter implements high-frequency resonance among discrete components and transformer parasitics to achieve high voltage gain, and the self-tracking nature ensures operation at maximum gain while power switches achieve zero-voltage switching across the full load range. This converter exhibits an inherent indefinite short-circuit capability. Theoretical results were obtained through simulations and verified by experimental results through a complete test configuration. Converter topology viability was confirmed through hardware testing and characterization.

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In today's industrial power converters, converter reliability is essential, and converter topologies are well-established. Without a doubt, the power electronic industry continues to seek efficient power delivery and high power density. Resonant converters, especially LLC converters, have been intensively studied and applied in DC-DC converters. One of the most demanding applications for LLC converters is data centers. To date, LLC Resonant converters, are deployed in many applications for improved efficiency, density, and reliability. With the introduction of WBG devices coupled with the soft switching feature, the switching frequency can be extended beyond Mega-Hertz. With the significant increase in operating frequency, complicated magnetic components can be broken down into a cellular structure, each with a few number of turns. They can be easily implemented using 4-6 layers of PCB windings. Moreover, integrating the cellular cores using flux cancellation can further improve the power density. The proposed integrated magnetics can be automated in the manufacturing process. The magnetic size is reduced at this frequency, and planar magnetics using PCB winding become more relevant. PCB magnetics feature multiple advantages over Litz wire. The benefits are summarized as follows: The labor-intensive manufacturing process can be automated, thus reduction of cost. There is much reduced CM noise by using the shield layer. They have parasitics with much-improved reproducibility in large quantities. PCB windings feature less leakage between transformer windings because of the flexibility of the winding interleaving and the reduced number of turns. There is better thermal management due to the increased surface-to-body ratio. The design has a low profile and high-power density. However, it is not without its own limitations. There are challenges for high frequency PCB-magnetic magnetic design for the LLC converter. Firstly, With the recently developed high frequency core material, a phenomenon referred to as the dimensional resonant is observed. The effects of dimensional resonance were discussed in the literature when using an unusually large core structure; however, it can be observed more frequently under high excitation frequency, particularly with integrated magnetics. This dissertation discusses the dimensional effects of core loss on a PCB-based magnetics structure. A case study is presented on a 3-kW 400-to-48-V LLC prototype running at 1 MHz. The converter utilizes a low-profile matrix of two integrated transformers with a rectangular and thin cross-section area for reduced core loss. Specific solutions are presented. % Secondly, The matrix transformer is suitable for an LLC converter with high output current. However, the matrix transformer also increases the core size and core losses. The core loss degrades the LLC converter's light load and peak efficiency. In this dissertation, We discuss the design process and implementation of the DC-DC stage of the power supply unit for narrow range 48 V data center bus architecture. The optimization takes into account the number of elemental transformers, number of transformer turns, switching frequency, and transformer dimensions, namely winding width and core cross-section area. The optimization process results in a nearly 99% efficient 400-to-48-V LLC with a very high-power density and low profile fully integrated on PCB. A matrix of four transformers is used to reduce the termination loss of the secondary synchronous rectifier and achieve better thermal management. The number of secondary turns is optimized to achieve the best trade-off between winding loss, core loss, and power density. Another challenge arises for magnetic integration when multiple magnetic components with different characteristics come together. For instance, in the case of a transformer and an inductor on the same PCB. The PCB transformer is designed with perfectly interleaved primary and secondary layers to utilize the full PCB layer thickness. As a rule of thumb, the transformer winding layer is designed within 1 to 2 times the skin depth. On the other hand, the inductor's winding lacks interleaving and suffers from high MMF stress on layers. This makes the inductor prone to high eddy currents and eddy loss. Furthermore, this dissertation addresses the challenges associated with the high winding and core loss in the Integrated Transformer-Inductor (ITL). To overcome these challenges, we propose an improved winding design of the ITL by utilizing idle shielding layers for inductor integration within the matrix transformer. This method offers full printed circuit board (PCB) utilization, where all layers are consumed as winding, resulting in a significant reduction in the winding loss of the ITL. Moreover, we propose an improved core structure of the ITL that offers better flux distribution of the leakage flux within the magnetic core. This method reduces the core loss by more than 50% compared to the conventional core structure. We demonstrate the effectiveness of our proposed concepts by presenting the design of the ITL used in a high-efficiency, high-power-density 3-kW 400-to-48-V LLC module. The proposed converter achieves a peak efficiency of 98.7% and a power density of 1500 W/in3. This dissertation presents the concept of matrix inductors to solve such problems. A matrix of four resonant inductors is also designed to reduce the proximity effect between inductor windings and reduce inductor PCB winding loss. The matrix inductor provides a solution for high thermal stress in PCB-based inductors and reduces the inter-winding capacitance between inductor layers. This dissertation solves the challenges in magnetic design in high-frequency DC-DC converters in offline power supplies and data centers. This includes the transformer and inductor of the LLC converter. With the academic contribution in this dissertation, Wide-bandgap devices WBG can be successfully utilized in high-frequency DC-DC converters with Mega-Hertz switching frequency to achieve high efficiency, high power density, and automated manufacturing. The cost will be reduced, and the performance will be improved significantly. / Doctor of Philosophy / Industrial power converters need to be reliable and efficient to meet the power industry's demand for efficient power delivery and high power density. Research should focus on improving existing converter designs to improve fabrication, efficiency, and reliability. Resonant converters have been found to be effective in power conversion, especially in data centers where energy consumption is high. Three-element Resonant converters (LLC) are already used to improve efficiency, density, and reliability. By using Wide Bandgap devices and soft switching, the switching frequency can be extended beyond MHz, simplifying magnetic components and improving power density. The proposed integrated magnetics can be automated during the manufacturing process, further improving power density. At higher frequencies, planar magnetic components made with PCB winding are more effective than Litz wire. They are cheaper to make because of automation, have less common-mode noise, and are more reproducible in large quantities. PCB winding also has a low profile, high-power density, and better thermal management. However, it is not without its own limitations. There are challenges for high frequency PCB-magnetic magnetic design for the LLC converter. Firstly, With the recently developed high frequency core material, a phenomenon referred to as the dimensional resonant is observed. The effects of dimensional resonance were discussed in the literature when using an unusually large core structure; however, it can be observed more frequently under high excitation frequency, particularly with integrated magnetics. This dissertation discusses the effects of core loss on a PCB-based magnetics structure and presents solutions, including a case study on a 3-kW 400-to-48 V LLC prototype running at 1 MHz. Another challenge arises for magnetic integration when multiple magnetic components with different characteristics come together. For instance, in the case of a transformer and an inductor on the same PCB. The PCB transformer is designed with perfectly interleaved winding and low Ohmic loss. On the other hand, the inductor's winding lacks interleaving and suffers from a high proximity field. This makes the inductor prone to high eddy currents and eddy loss. This dissertation presents the concept of matrix inductors to solve such problems. A matrix of four resonant inductors is also designed to reduce the proximity effect between inductor windings and reduce inductor PCB winding loss. The matrix inductor provides a solution for high thermal stress in PCB-based inductors and reduces the inter-winding capacitance between inductor layers. Furthermore, this dissertation addresses the challenges associated with the high winding and core loss in the Integrated Transformer-Inductor (ITL). To overcome these challenges, we propose an improved winding design of the ITL by utilizing idle shielding layers for inductor integration within the matrix transformer. This method offers full printed circuit board (PCB) utilization, where all layers are consumed as winding, resulting in a significant reduction in the winding loss of the ITL. Moreover, we propose an improved core structure of the ITL that reduces the core loss by more than 50% compared to the conventional core structure. We demonstrate the effectiveness of our proposed concepts on a high-efficiency, high-power-density 3-kW 400-to-48-V LLC module. The proposed converter achieves a peak efficiency of 98.7% and a power density of 1500 W/in3. This dissertation solves the challenges in magnetic design in high-frequency DC-DC converters in offline power supplies and data centers. This includes the transformer and inductor of the LLC converter. With the academic contribution in this dissertation, Wide-bandgap devices WBG can be successfully utilized in high-frequency DC-DC converters with Mega-Hertz switching frequency to achieve high efficiency, high power density, and automated manufacturing. The cost will be reduced, and the performance will be improved significantly.

Faster charging and availability of charging infrastructure are the two main challenges facing an accelerated transition to sustainable electri ed transportation. Both challenges can be solved by developing modular charging systems that are future proof all while having low running and installation costs. As such, this thesis focuses on developing modular and e cient DC/DC charging solutions with a wide charging voltage range capability to meet the needs of existing and next generation plug-in electric vehicles. The thesis starts with describing its motivation and gives an overview on the impact of charging technologies on the electri fication movement. Then, specifi c objectives and research contributions are laid out to narrow the focus of the reader. A review on existing charging systems, standards, architecture and features is presented. Existing isolated and on-isolated power converter topologies for DC-chargers are analyzed and research gaps in power converters with a wide charging voltage range are highlighted. A new single stage DC/DC converter topology and operation scheme is proposed to extend the charging voltage range. Modeling and analysis of the proposed solution was used to select the transition point between different operating modes. Impedance tolerance and pulse distortion was modeled to analyze the passive current sharing error at light and full load operation. The combination of the proposed topology and unique operating scheme reduced the voltage and current stress per device allowing the use of lower kVA rated devices leading to higher cost savings compared to other solutions. An experimental setup has been developed which showed the excellent performance of the proposed topology. The design and optimization strategy for the proposed dual-secondary dual-active bridge (DAB) converter topology is presented. A converter loss model is developed to take in to account: magnetic, switching, and conduction loss. Then, the design process and quantization scheme to quantize charging pro les into discrete energy points is explained, which entails parametric optimization using a genetic algorithm (GA) to minimize energy loss across widely varying charging pro les based on actual charging data. Comprehensive experimental testing was carried out to validate the proposed design strategy and excellent performance was achieved over an extended operating range. After the review of power magnetics used in isolated chargers, high parasitic capacitance in planar transformers was identi ed as an obstacle in the way of development of chargers, especially in charging applications that demand high switching frequencies or extended low power operation. Therefore, a novel planar transformer structure was proposed with ultra-low winding capacitance. The proposed co-planar transformer was compared to three other planar types to highlight the differences and bene fits. Four different prototypes of planar transformers were built with the same target speci fications, to compare the proposed structure against previous solutions. Impedance testing of the planar prototypes was carried to measure the winding stray capacitance and frequency response. Experimental power testing using a DAB converter setup showed excellent results in reducing voltage overshoot, high frequency oscillations, and power losses. Finally, a 30-kW dual-secondary DAB charging module was designed, implemented, and tested. The purpose of this work is to bridge the engineering gap between a proof of concept and a higher Technology Readiness Level (TRL) mature charging module, focusing more on regulatory standards and control system development. Experimental validation of the liquid cooled module showed excellent performance characteristics. / Thesis / Doctor of Philosophy (PhD)

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