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New current sensing solutions for low-cost high-power-density digitally controlled power convertersZiegler, Silvio January 2009 (has links)
[Truncated abstract] This thesis studies current sensing techniques that are designed to meet the requirements for the next generation of power converters. Power converters are often standardised, so that they can be replaced with a model from another manufacturer without an expensive system redesign. For this reason, the power converter market is highly competitive and relies on cutting-edge technology, which increases power conversion efficiency and power density. High power density and conversion efficiency reduce the system cost, and thus make the power converter more attractive to the customer. Current sensing is a vital task in power converters, where the current information is required for monitoring and control purposes. In order to achieve the above-mentioned goals, existing current sensing techniques have to be improved in terms of cost, power loss and size. Simultaneously, current information needs to be increasingly available in digital form to enable digital control, and to allow the digital transmission of the current information to a centralised monitoring and control unit. All this requires the output signal of a particular current sensing technique to be acquired by an analogue-to-digital converter, and thus the output voltage of the current sensor has to be sufficiently large. This thesis thoroughly reviews contemporary current sensing techniques and identifies suitable techniques that have the potential to meet the performance requirements of the next-generation of power converters. After the review chapter, three novel current sensing techniques are proposed and investigated: 1) The usefulness of the resistive voltage drop across a copper trace, which carries the current to be measured, to detect electrical current is evaluated. Simulations and experiments confirm that this inherently lossless technique can measure high currents at reasonable measurement bandwidth, good accuracy and low cost if the sense wires are connected properly. 2) Based on the mutual inductance theory found during the investigation of the copper trace current sense method, a modification of the well-known lossless inductor current sense method is proposed and analysed. This modification involves the use of a coupled sense winding that significantly improves the frequency response. Hence, it becomes possible to accurately monitor the output current of a power converter with the benefits of being lossless, exhibiting good sensitivity and having small size. 3) A transformer based DC current sense method is developed especially for digitally controlled power converters. This method provides high accuracy, large bandwidth, electrical isolation and very low thermal drift. Overall, it achieves better performance than many contemporary available Hall Effect sensors. At the same time, the cost of this current sensor is significantly lower than that of Hall Effect current sensors. A patent application has been submitted. .... The current sensing techniques have been studied by theory, hardware experiments and simulations. In addition, the suitability of the detection techniques for mass production has been considered in order to access the ability to provide systems at low-cost.
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