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Distributed energy is an attractive alternative to typical centralized energy sources specifically for remote locations not accessible to the electricity grid. With the continued advancement into new renewable technologies like solar, wind, fuel cell etc., off-grid standalone systems are becoming more attractive and even compeating on a cost basis for rural locations. Along with the environmental and sustainable movement, these technologies are only going to get more and more popular as time goes on. Power electronic converters are also advancing which will help the shift in electricity options. Creating innovative power electronic systems will be important when moving toward smaller, more e cient and higher power density solutions. As such, this thesis will aim to design and create an integrated power electronic system for an o -grid standalone solar application designed for remote rural locations with no access to electricity, or in locations which could bene t from such a system. It is designed for a DC input source from 24V-40V, such as a solar panel, and can operate four di erent loads; one 12V-24V 100 W DC load, charge a 48V battery, run three 5V cell phone charger outputs and run one 230V, 50Hz, 1 kW AC load. A boost converter, buck converter, phase shifted full bridge isolated DC-DC converter and a single phase inverter are implimented in the integrated system to achieve these outputs. A comparison of similar products on the market are presented and compared with the proposed design by showing the product speci cations, advantages and disadvantages of each. A discussion of each converter in the system is presented and will include operation, design and component selection. An in-depth design process for the inductor within the boost converter is presented and will cover core, winding design and an optimization algorithm using the Genetic Algorithm (GA) is used to compare di erent ferrite based C-C shaped inductors. More speci cally, the core material selected is Ferroxcube 3C97 and the inductor comparions are between di erent Litz bundled windings from New England Wire Tecnologies and a customized rectangular winding. The GA optimizes around the lowest volume by comparing the di erent inductor designs using the di erent Litz winding constructions and the custom rectangular winding constrictuion. The rectangular winding achieves the lowest volume and will be compared with a three phase interleaved boost design implimenting a CoilCraft inductor. The buck converter is the simplest converter and is designed using the traditional methods in literature. An in-depth design process for the phase shifted full bridge converter is also done wherein the zero voltage switching (ZVS) is achieved. The DC-AC inverter is the last converter designed within the integrated system and covers input capacitor sizing, and output lter design. There are speci c distributed energy standards that must be followed when connecting loads to the system and so the purpose of the lter is to lter out the voltage harmonics. The control techniques for each converter is also discussed and shown to operate in both simulation and in experimentally. The losses within the system are discussed and the required equations are de ned / Thesis / Master of Applied Science (MASc)

This work explores the design, construction, and analysis of a novel DC-DC converter which incorporates combinations of switching capacitors and inductors to achieve an integer voltage divider function, without the need for a feedback loop controller to achieve the desired output voltage. The proposed Hybrid Voltage Divider additionally provides zero voltage switching (ZVS) at turn on transitions which yields improved overall efficiency of the converter. Besides a proof-of-concept via computer simulations, another primary goal of this thesis is to demonstrate the functionalities of the proposed Zero Voltage Switching Hybrid Voltage Divider (ZVS-HVD) through hardware prototyping. The proposed ZVS-HVD was designed and constructed to provide a 2:1 division with 24V input voltage at 120W maximum output power utilizing 500kHz switching frequency. Findings from simulations and hardware tests verify that the converter effectively provides the desired 12V output at varying loads with less than 5% voltage ripple. The efficiency of the converter reaches 95.02% at full load and peak efficiency of 96.33% at 55% load. Moreover, the converter consistently maintains the ZVS operations across all switches under varying loads. Overall, results verify the feasibility of the proposed ZVS HVD converter as an alternative solution in providing high efficiency DC voltage division without the need for complex feedback circuitry.

With the fast advance in VLSI technology, smaller, more powerful digital system is available. It requires power supply with higher power density, lower profile and higher efficiency. PWM topologies have been widely used for this application. Unfortunately, hold up time requirement put huge penalties on the performance of these topologies. Also, high switching loss limited the power density achievable for these topologies. Two techniques to deal with hold up time issue are discussed in this dissertation: range winding solution and asymmetric winding solution, the efficiency at normal operation point could be improved with these methods. To reduce secondary rectifier conduction loss, QSW synchronous rectifier is developed, which also helps to achieve ZVS for symmetrical half bridge converter. Although with these methods, the efficiency of front end DC/DC converter could be improved, the excessive switching loss prohibited higher switching frequency. To achieve the targets, topologies with high switching frequency and high efficiency must be developed. Three resonant topologies: SRC, PRC and SPRC, are been investigated for this application because of their fame of low switching loss. Unfortunately, to design with hold up requirement, none of them could provide significant improvements over PWM converter. Although the negative outcome, the desired characteristic for front end application could be derived. Base on the desired characteristic, a thorough search is performed for three elements resonant tanks. LLC resonant topology is found to posses the desired characteristic. From comparison, LLC resonant converter could reduce the total loss by 40% at same switching frequency. With doubled switching frequency, efficiency of LLC resonant converter is still far better than PWM converters. To design the power stage of LLC resonant converter, DC analysis is performed with two methods: simulation and fundamental component simplification. Magnetic design is also discussed. The proposed integrated magnetic structure could achieve smaller volume, higher efficiency and easy manufacture. To make practical use of the topology, over load protection is a critical issue. Three methods to limit the stress under over load situation are discussed. With these methods, the converter could not only survive the over load condition, but also operate for long time under over load condition. Next small signal characteristic of the converter is investigated in order to design the feedback control. For resonant converter, state space average method is no longer valid. Two methods are used to investigate the small signal characteristic of LLC resonant converter: simulation and extended describing function method. Compare with test results, both methods could provide satisfactory results. To achieve both breadth and depth, two methods are both used to reveal the myth. With this information, compensator for feedback control could be designed. Test circuit of LLC resonant converter was developed for front end DC/DC application. With LLC topology, power density of 48W/in3 could be achieved compare with 13W/in3 for PWM converter. / Ph. D.

Fuel cells are a clean, high-efficiency source for power generation. This innovative technology is going to penetrate all aspects in our life, from utility distributed power, transportation applications, down to power sources for portable devices such as laptop computer and cell phones. To enable the usage of fuel cell, developing power converters dedicated for fuel cells becomes imminent. Currently, the full-bridge converter is the dominating topology in high power dc/dc applications. Although multiphase converters have been proposed, most of them are dealing with high input-voltage systems, and their device characteristic is not suitable for a low voltage source such as a fuel cell. For a high power fuel cell system, high voltage conversion ratios and high input currents are the major obstacles to achieving high-efficiency power conversions. This dissertation proposes a novel 3-phase 6-leg dc/dc power converter with transformer isolation to overcome these obstacles. Major features of the proposed converter include: (1) Increase converter power rating by paralleling phases, not by paralleling multiple devices; (2) Double the output voltage by transformer delta-wye connection, thus lowering the turns-ratio; (3) Reduce the size of output filter and input dc bus capacitor with interleaved control; (4) Achieve Zero-Voltage Zero-Current Switching (ZVZCS) over a wide load range without auxiliary circuitry. High conversion efficiency above 96% is verified with different measurement approaches in experiments. This dissertation also presents the power stage and control design for the proposed converter. Control design guideline is provided and the design result is confirmed with both simulation and hardware experiments. When using the fuel cell for stationary utility power applications, a low-frequency ripple interaction was identified among fuel cell, dc/dc converter and dc/ac inverter. This low frequency ripple tends to not only damage the fuel cell, but also reduce the source capability. This dissertation also investigates the mechanism of ripple current propagation and exploits the solutions. A linearized ac model is derived and used to explain the ripple propagation. An active ripple reduction technique by the use of the current loop control is proposed. This active current loop control does not add extra converters or expensive energy storage components. Rather, it allows a reduction in capacitance because the ripple current flowing into the capacitor is substantially reduced, and less capacitance can be used while maintaining a clean dc bus voltage. The design process and guideline for the proposed control is suggested, and the effectiveness of this active control is validated by both simulation and experimental results. / Ph. D.

With the increasing demand for clean and renewable energy, new distribution network concepts, such as DC microgrids and distributed power generation networks, are being developed. One key component of such networks is the grid-interfacing DC-DC power converter that can transfer power bi-directionally while having a wide range of voltage step-up and step-down capabilities. Also, with the proliferated demand for electric vehicle chargers, battery energy storage systems, and solid-state transformers (SST), the bi-directional high-power DC-DC converter plays a more significant role in the renewable energy industry. To satisfy the requirements of the high-power bi-directional wide-range DC-DC converter, different topologies have been compared in this thesis, and the four-switch buck-boost (FSBB) converter topology has been selected as the candidate. This work investigates the operation principle of the FSBB converter, and a digital real-time low-loss quadrangle current mode(QCM) control implementation, which satisfies the zero-voltage-switching (ZVS) requirements, is proposed. With the QCM control method, the FSBB converter efficiency can be further increased by reducing the inductor RMS current and device switching loss compared to traditional continuous current mode(CCM) control and discontinuous current mode(DCM) control. Although the small signal model has been derived for FSBB under CCM control, the small ripple approximation that was previously used in the CCM model no longer applies in the QCM model and causing the model to be different. To aid the control system compensator design, QCM small signal model is desired. In this thesis, a small signal model for FSBB under QCM control is proposed. A 50 kW silicon carbide (SiC) based grid-interfacing converter prototype was constructed to verify the QCM control implementation and small signal model of the FSBB converter. For driving the 1.2kV SiC modules, an enhanced gate driver with fiber optic (FO) based digital communication capability was designed. Digital on-state and off-state drain-source voltage sensors and Rogowski coil-based current sensors are embedded in the gate driver to minimize the requirement for external sensors, thus increasing the power density of the converter unit. Also, Rogowski-coil-based current protection and drain-source voltage-based current protection is embedded in the gate driver to prevent SiC switching device from damage. / Master of Science / The renewable energy sector is driving the development of new distribution networks, such as DC microgrids and distributed power generation networks. One crucial component of these networks is the grid-interfacing DC-DC power converter, which can transfer power in both directions while maintaining a wide voltage range. This study evaluates various topologies and selects the four-switch buck-boost (FSBB) converter topology to meet the demands of high-power, bi-directional, and wide-range DC-DC converters. This work analyzed the operation of the FSBB converter and proposed a novel simplified quadrangle current mode (QCM) control implementation. With the QCM control method, the FSBB converter efficiency can be further improved by reducing losses compared to conventional control methods. This study also provides a small signal model, which can be used to aid the control loop compensator design where application of FSBB converter is required. A 50 kW silicon carbide (SiC) based grid-interfacing converter prototype, which was constructed to validate the proposed QCM control implementation and small signal model of the FSBB converter. As part of the converter unit,the enhanced gate driver design and implementation is presented in this thesis. This gate driver is designed with fiber optic-based digital communication, drives the wide bandgap SiC modules. The gate driver also features embedded digital on-state and off-state drain-source voltage sensors and non-intrusive current sensors to minimize external sensor requirements, thereby increasing the power density of the converter unit. The gate driver also incorporates high bandwidth current protection and drain-source voltage-based current protection to protect the SiC switching device from damage.

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