The low-voltage dc-dc converter (LDC) in electrical vehicles (EVs) is to convert high dc voltage (270V~430V) from traction battery to low dc voltage (12.5V~15.5V) for the vehicle auxiliary systems. Galvanic isolation is required in the LDC due to safety considerations. Three challenges exist in the LDC design: (1) wide regulation range; (2) high output current; (3) thermal management. The single stage solutions, such as phase-shift full-bridge converter and LLC resonant converter, have been widely studied in the past. A matrix transformer is widely adopted in single-stage LDC design to deal with the large current. At last, the low-profile design allows large footprint area for high power density and ease of cooling design. However, the trade-off between wide regulation range and efficiency exists in single-stage LDC design. Recently, a two-stage solution is proposed to achieve high efficiency and wide regulation range at the same time. The fixed turn ratio LLC stage serves as a dc transformer (DCX) to meet the galvanic isolation requirements and PWM dc-dc stage regulates the output voltages. In this thesis, a variable ratio matrix transformer-based LLC converter is proposed for two-stage LDC efficiency improvement. The transformer secondary copper losses are reduced by taking advantage of the adaptive number of element transformers. In addition, the PWM dc-dc stage achieves better efficiency with variable intermediate bus voltage. The operation principle and design considerations are studied in this thesis. The proposed 1600W two-stage LDC prototype achieves 96.82% full load efficiency under 400V input condition which is 1.2% efficiency higher than the fixed ratio LLC based two-stage design. Last but not least, the prototype shows a comparable efficiency to the fixed ratio LLC based two-stage design even under the low input voltage (270V) condition. / M.S. / The electrical vehicle market is growing rapidly in recent years. However, the driving range is one of the bottlenecks which imperils market growth in the future. Thus, efficient power modules in electric vehicles are desired to extend the driving range. Low voltage dc-dc converter is one of the power modules in electric vehicles which is rated at several kilowatts and converts traction battery voltage for the vehicle auxiliary system, such as air conditioner, headlights, power steering and etc. In this thesis, a variable ratio matrix transformer-based LLC converter is proposed for the two-stage low-voltage dc-dc converter efficiency improvement. Consequently, the driving range of electric vehicles is further extended.

The wide-bandgap (WBG) devices, like gallium nitride (GaN) and silicon carbide (SiC) devices have proven to be a driving force of the development of the power conversion technology. Thanks to their distinct advantages over silicon (Si) devices including the faster switching speed and lower switching losses, WBG-based power converter can adopt a higher switching frequency and pursue higher power density and higher efficiency. As a trade-off of the advantages, there also exist the high-frequency-oriented challenges in the adoption of the GaN HEMT under research, including narrow safe gate operating area, increased switching overshoot, increased electromagnetic interference (EMI) in the gate loop and the power stages, the lack of the modules of packages for high current application, high gate oscillation under parallel operation. The dissertation is developed to addressed the all the challenges above to fully explore the potential of the GaN HEMTs. Due to the increased EMI emission in the gate loop, a small isolated capacitor in the gate driver power supply is needed to build a high-impedance barrier in the loop to protect the gate driver from interference. A 2 W dual-output gate driver power supply with ultra-low isolation capacitor for 650 V GaN-based half bridge is presented, featuring a PCB-embedded transformer substrate, achieving 85% efficiency, 1.6 pF isolation capacitor with 72 W/in3 power density. The effectiveness of the EMI reduction using the proposed power supply is demonstrated. The design consideration to build a compact 650 V GaN switching cell is presented then to address the challenges in the PCB layout and the thermal management. With the switching cell, a compact 1 kW 400 Vdc three-phase inverter is built and can operate with 500 kHz switching frequency. With the inverter, the high switching frequency effects on the inverter efficiency, volume, EMI emission and filter design are assessed to demonstrate the tradeoff of the adoption of high switching frequency in the motor drive application. In order to reduce the inverter CM EMI emission above 10 MHz, an active gate driver for 650 V GaN HEMT is proposed to control the dv/dt during turn-on and turn-off independently. With the control strategy, the penalty from the switching loss can be reduced. To build a high current power converter, paralleling devices is a normal approach. The dissertation comes up with the switching cell design using paralleled two and four 650 V GaN HEMTs with minimized and symmetric gate and power loop. The commutation between the paralleled HEMTs is analyzed, based on which the effects from the passive components on the gate oscillation are quantified. With the switching cell using paralleled GaN HEMTs, a 10 kW LLC resonant converter with the integrated litz-wire transformer is designed, achieving 97.9 % efficiency and 131 W/in3 power density. The design consideration to build the novel litz-wire transformer operated at 400 kHz switching frequency is also presented. In all, this work focuses on providing effective solutions or guidelines to adopt the 650 V GaN HEMT in the high frequency, high power density, high efficiency power conversion and demonstrates the advance of the GaN HEMTs in the hard-switched and soft-switched power converters. / Ph. D. / Silicon (Si) -based power semiconductor has developed several decades and achieved numerous outstanding performances, contributing a fast development of the power electronics. While the theatrical limit of the silicon semiconductor is almost reached limiting the progress speed to purse the high-efficiency, high-density high-reliability power conversion, the new material, including gallium-nitride (GaN) and silicon-carbide (SiC), based semiconductor, becomes the driven force to retain the development. Compared with Si-based device, GaN and SiC device own a faster switching speed and a lower on-resistance, enabling the adoption of high switching frequency and the possibility to increase the efficiency, power density and dynamic response. The GaN-based semiconductor is explored to be an even promising game changer than SiC device thanks to a higher theoretical ceiling. However, to adopt GaN-based semiconductors and fully utilize its benefits with high switching frequency, there are numerous high-frequency-oriented challenges, including high frequency oscillation at device termination, increased electromagnetic interference (EMI), the lack of the modules of packages for high current application, high frequency oscillation under parallel operation. The dissertation is developed to address the key high-frequency-oriented challenges to adopt GaN-based semiconductors in the power conversion and come up with the novel design strategy and analysis for high-switching-frequency power conversion using GaN devices. To the reduce the increased EMI emission in the gate loop, a novel PCB-embedded transformer structure is proposed to maintain a low isolation capacitor in the gate driver power supply for the GaN phase leg. With the proposed technique, the dual-output gate driver power supply can achieve high efficiency (85%), ultra-low isolation capacitor (1.6 pF) with high power density (72 W/in³ ). To reduce the high frequency oscillation at the GaN device termination, the strategy to layout GaN devices and its gate driver is proposed with corresponding thermal management. A compact structure for three-phase inverter is then presented, operating with a very high switching frequency (500 kHz). Within the inverter, the high switching frequency effects on the inverter performances are assessed to demonstrate the tradeoff and bottle neck to adopt high switching frequency in the motor drive application. In order to reduce the inverter EMI emission at high frequency ( >10 MHz), an active gate driver for GaN device is proposed for the active dv/dt control strategy. To build a high current power converter, the strategy to parallel GaN devices is proposed in the dissertation with the analysis on the commutation between the paralleled GaN devices. A high-frequency high-current litz-wire transformer structure for LLC resonant converter is presented with modeling and optimization. With the technique, a 10 kW LLC resonant converter achieves high efficiency (97.9 %) and high power density (131 W/in³).

As information technology advances, so does the demand for power management of telecom and computing equipment. High efficiency and high power density are still the key technology drivers for power management for these applications. In order to save energy, in 2005, the U.S. Environmental Protection Agency (EPA) announced the first draft of its proposed revision to its ENERGY STAR specification for computers. The draft specification separately addresses efficiency requirements for laptop, desktop, workstation and server computers. The draft specification also proposes a minimum power supply efficiency of 80% for PCs and 75% to 83% for desktop derived servers, depending on loading condition and server type. Furthermore, recently some industry companies came out with a much higher efficiency target for the whole AC/DC front-end converter over a wide load range. Distributed power systems are widely adopted in the telecom and computing applications for the reason of high performance and high reliability. As one of the key building blocks in distributed power systems, DC/DC converters in the front-end converter are also under the pressure of increasing efficiency and power density. Due to the hold-up time requirement, PWM DC/DC converters cannot achieve high efficiency for well known reasons when they are designed for wide input voltage range. As a promising topology for this application, LLC resonant converters can achieve both high efficiency and wide input voltage range capability because of its voltage gain characteristics and small switching loss. However, the efficiency of LLC resonant converter with diode rectifier still cannot meet the recent efficiency target from industry. In order to further improve efficiency of LLC resonant converters, synchronous rectification must be used. The complete solution of synchronous rectification of LLC resonant converters is discussed in this thesis. The driving of the synchronous rectifier can be realized by sensing the voltage Vds of the SR. The turn-on of the SR can be triggered by the body-diode conduction of the SR. With the Vds compensation network, the precise voltage drop on Rds_on can be achieved, thus the SR can be turned off at the right time. Moreover, efficiency optimization at normal operation over wide load range is discussed. It is revealed that power loss at normal operation is solely determined by the magnetizing inductance while the magnetizing inductor is designed according to dead-time td selection. The mathematic equations for the relationship between power loss and dead-time are developed. For the first time, the relationship between power loss and dead-time is used as a tool for efficiency optimization. With this tool, the efficiency optimization of the LLC resonant converter can be made according to efficiency requirement over a wide load range. With the expectation to achieve high efficiency at ultra-light load, the green mode operation of LLC resonant converters is addressed. The rationale of the issue with the conventional control algorithm is revealed and a preliminary solution is proposed. / Master of Science

An ever present trend in the power conversion industry is to get higher performance at a lower cost. In a computer server system, the front-end converter, supplying the load subsystems, is typically a multiple output power supply. The power supply unit is custom designed and its output voltages are fully regulated, so it is not very efficient or cost effective. Most of the load systems in this application are supplied by point-of-load converters (POLs). By leaving the output voltage regulation aspect to POLs, the front-end converter does not need to be a fully regulated, multiple output converter. It can be replaced by a dc-dc transformer (DCX), which is a semi-regulated or unregulated, single output dc-dc converter. A DCX can be made using a modular design to simplify expansion of the system capacity. To realize this concept, the DCX block must have a current sharing feature. The current sharing method for a resonant DCX is discussed in this work. To simplify the system architecture, the current sharing method is based on the droop method, which requires no communication between paralleled units. With this method, the current sharing error is inversely proportional to the droop voltage. In traditional DCX implementations, the droop voltage depends on the resistive voltage drops in the power stage, which is not sufficient to achieve the desired current sharing error. The resonant converter has the inherent characteristic that its conversion gain depends on the load current, so the virtual droop resistance can realized by the resonant tank and the droop voltage can be obtained without incurring conduction loss. An LLC resonant converter is investigated for its droop characteristic. The study shows the required droop voltage is achievable at very high switching frequency. To lower the switching frequency, a notch filter is introduced into the LLC resonant tank to increase the sensitivity of the conversion gain versus the operating frequency. The design of the multi-element resonant tank is discussed. Depending soly on the resonant tank, the droop characteristic is largely varied with the component tolerance in the resonant tank. The current sharing error becomes unacceptable. The active droop control is imposed to make the output regulation characteristic insensitive to the component tolerance. The proposed resonant DCX has simpler circuit structure than the fully regulated resonant converter. Finally simulation and experimental results are presented to verify this concept. / Master of Science

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

Recently, as a promising lighting source, light-emitting diodes (LEDs) have become more and more attractive and have great opportunity to replace traditional lighting sources - incandescent, fluorescent and HID because of the advantages such as high luminous efficacy, long lifetime, quick on/off time, wide color gamut, eco-friendly etc. Based on the research from U.S. Department of Energy, over 30% of total electric consumption in U.S. each year is for lighting, 75% of which are for indoor lighting (including both residential and commercial buildings). In the indoor LED lighting application, to provide multiple current source outputs for multiple LED strings, traditional solutions usually adopt a two-stage structure, which is complicated and cost-ineffective. How to design a simple, low-cost and efficient LED driver with multiple current source outputs is in great demand and really challenging. In this thesis, a single-stage multi-channel constant current (MC3) LED driver structure has been proposed. Multiple transformer structure is utilized to provide multiple current source outputs. The current control scheme is also simple - only one LED string current is sensed and controlled; other strings' currents are cross regulated. Firstly, a PWM half bridge topology is chosen to implement the proposed single-stage MC3 LED driver concept. In order to analyze the current cross regulation, a general model is derived. The circuit has been simulated under various LED load conditions to verify its good current sharing capability. In order to further improve efficiency, simplify the driver's complexity and reduce cost, a LLC resonant topology is also investigated. LLC current gain characteristic has been derived by considering LED's i-v character and a design procedure is developed. A 100 kHz, 200 W, 4-string MC3 LLC LED driver is designed and tested. The experimental results show that the driver can maintain constant current output within the whole input and output variations, achieve good efficiency and realize current sharing under both balanced and unbalanced LED conditions. The dimming function can also be realized through frequency modulation method and burst mode control method. As a conclusion, a single-stage MC3 LED driver concept is proposed and implemented with two topologies. The proposed idea provides a simple, low-cost and efficient solution for indoor LED lighting application with multiple LED string configuration. It also has good current sharing capability and robustness to LED forward voltage variations or short failures. / Master of Science

Cette thèse traite de la conception d’un convertisseur DC / DC destiné aux véhicules électriques et hybrides (2,5 kW, 400V/14V, 250kHz). Dérivé de la topologie LLC à résonance, ce convertisseur bénéficie des nombreux avantages propres à cette structure particulière. C’est ainsi que le prototype réalisé présente un rendement très élevé, une densité de puissance très forte avec des perturbations EMI très réduites. La première partie de cette thèse est consacrée à l’analyse théorique du circuit LLC afin de dégager un modèle de conversion et une stratégie de contrôle adaptée à l’application visée. Afin de conserver un rendement important sur une large plage de charge, une structure basée sur la mise en parallèle de deux modules LLC est proposée. Une nouvelle stratégie de contrôle à deux boucles est également proposée pour équilibrer le courant entre les deux modules. La seconde partie de la thèse fait appel à la simulation et à l’expérimentation. Il s’agit de minimiser la masse et l’encombrement tout en maximisant le rendement. Un composant magnétique spécial est conçu puis dimensionné pour intégrer le transformateur et diverses inductances de résonance. Ce convertisseur met également en œuvre un système de redressement synchrone robuste avec une compensation de phase, un module de puissance avec une résistance thermique très faible et un système de refroidissement efficace par air. Le rendement maximal mesuré est 95%. Le rendement demeure supérieur à 94% sur une plage de puissance s’étalant de 500 W à 2 kW. La densité de puissance est 1W/cm3. La CEM du convertisseur est développée dans cette thèse. / In this dissertation, a 2.5kW 400V/14V, 250kHz DC/DC converter prototype is developed targeted for electric vehicle/hybrid vehicle applications. Benefiting from numerous advantages brought by LLC resonant topology, this converter is able to perform high efficiency, high power density and low EMI. A first part of this dissertation is the theoretical analysis of LLC: topology analysis, electrical parameter calculation and control strategy. To arrange high output current, this thesis proposes parallel connected LLC structure with developed novel double loop control to realize an equal current distribution. The second part concerns on the system amelioration and efficiency improvement of developed LLC. A special transformer is dimensioned to integrate all magnetic components, and various types of power losses are quantified based on different realization modes and winding geometries to improve its efficiency. This converter also implements a robust synchronous rectification system with phase compensation, a power semiconductor module, and an air-cooling system. The power conversion performance of this prototype is presented and the developed prototype has a peak efficiency of 95% and efficiency is higher than 94% from 500W to 2kW, with a power density of 1W/cm3. The CEM analysis of this converter is also developed in this thesis.

This thesis deals with the issue of switching power supply in terms of noise ratios in the output voltage. In the theoretical part analyzes the basic principle of classical and resonant topology switching power converters in terms of output voltage ripple and switching noise. There are also some possibilities of compensation to minimize switching noise and output ripple. The second part describes the custom design a low noise switching power supply, which is composed of an active power factor corrector, power converters and ripple limiter. The main power converter is designed as an LLC resonant converter. The last part deals with the actual construction of the proposed source, its measurement and presentation of the results.

Isolated inverter can provide galvanic isolation which is necessary for some applications with safety regulations. Traditionally, a two-stage configuration is widely applied with isolated dc-dc stage and a sinusoidal pulse-width-modulated (SPWM) dc-ac stage. However, this two-stage configuration suffers from more components count, more complex control and tend to have lower efficiency and lower power density. Meanwhile, a large dc bus capacitor is needed to attenuate the double line frequency from SPWM for two-stage configuration. Therefore, the single-stage approach including an isolated dc-rectified sine stage and a line frequency unfolder is preferable. Since the unfolder circuit is at line frequency being almost lossless, the isolated dc-rectified sine stage becomes critical. However, the relevant research for the single-stage isolated inverter is limited. People either utilize PWM based converter as dc-rectified sine stage with duty cycle adjustment or apply SRC or LLC resonant converter for better soft switching characteristics. For PWM based converter, hard switching restricts the overall inverter efficiency, while for SRC/LLC, enough wide voltage gain range and full range ZVS are the major issues. This dissertation aims to provide solutions for a high-efficiency, high-frequency resonant converter based single-stage soft-switching isolated inverter design. The LLC and LCLCL resonant converters are applied as the isolated dc-rectified sine stage with variable frequency modulation (VFM). Therefore, the rectified sine wave generation consists of many dc-dc conversion with different switching frequencies and an efficient dc-rectified sine stage design needs each dc-dc conversion to be with high efficiency. This dissertation will first propose the optimization methods for LLC converter dc-dc conversion. ZVS models are derived to ensure fully ZVS performance for primary side GaN devices. As a large part in loss breakdown, the optimization for transformer is essential. The LLC converter can achieve above 99% efficiency with proposed optimization approach. Moreover, the channel turn-off energy model is presented for a more accurate loss analysis. With all the design and optimization considerations, a MHz LLC converter based isolated inverter is designed and a hybrid modulation method is proposed, which includes full bridge (FB) VFM for output high line region and half bridge (HB) VFM for output low line region. By changing from FB to HB, the output voltage gain is reduced to half to have a wider voltage gain range. However, the total harmonic distortion (THD) of output voltage at light load will be impacted since the voltage gain will be higher with lighter load at the maximum switching frequency. A MHz LCLCL converter based isolated inverter is proposed for a better output voltage THD at light load conditions. The paralleled LC inside the LCLCL resonant tank can naturally create a zero voltage gain point at their resonant frequency, which shows superior performance for rectified sine wave generation. Besides the better THD performance, the LCLCL converter based isolated inverter also features for easier control, better ZVS performance and narrower switching frequency range. Meanwhile, the LCLCL based inverter topology has bi-directional power flow capability as well. With variable frequency modulation for ac-dc, this topology is still a single-stage solution compared to the traditional two-stage solution including PFC + LLC configuration. / Doctor of Philosophy / Inverters can convert dc voltage to ac voltage and typically people use two-stage approach with isolated dc-dc stage and dc-ac stage. However, this two-stage configuration suffers from more components count, more complex control and tend to have lower efficiency and lower power density. Therefore, the single-stage solution with dc-rectified sine wave stage and a line frequency unfolder becomes appealing. The unfolder circuit is to unfold the rectifier sine wave to an ac sine wave at the output. Since the unfolder is at line frequency and can be considered lossless, the key design is for the dc-rectified sine stage. The resonant converter featured for soft switching seems to be a good candidate. However, the inverter needs soft switching for the whole range and an enough wide voltage gain, which makes the design difficult, especially the target is high efficiency for the overall inverter. This dissertation aims to provide solutions for a high-efficiency, high-frequency resonant converter based single-stage soft-switching isolated inverter design. The LLC and LCLCL resonant converters are applied as the isolated dc-rectified sine stage with variable frequency modulation (VFM). Therefore, the rectified sine wave generation consists of many dc-dc conversion with different switching frequencies and an efficient dc-rectified sine stage design needs each dc-dc conversion to be with high efficiency. The design considerations and optimization methods for the LLC dc-dc conversion are firstly investigated. Based on these approaches, a MHz LLC converter based isolated inverter is designed with proposed hybrid modulation method. To further improve the light load performance, a MHz LCLCL converter based isolated inverter topology is proposed. The paralleled LC inside the LCLCL resonant tank can naturally create a zero voltage gain point which shows superior characteristics for rectified sine wave generation. Moreover, the LCLCL resonant converter based topology has bi-directional capability as well so it can work well for ac voltage to dc voltage conversion.

The project deals with the design of a switch-mode power supply (SMPS) with a medium and high power output. The power supply uses multiphase control switching. Electric energy is converted through a series parallel LLC resonant circuit to reach the maximum efficiency with a small size and cost efficiency of the designed power supply. The semiconductor switches use ZVS (Zero Voltage Switching) on the primary side and ZCS (Zero Current Switching) on the secondary side of the converter. The design of the converter is based on the knowledge of the high power output converters (types of switching, art topologies) and resonant topologies (series resonant circuit – SRC, parallel resonant circuit – PRC and series parallel circuit –SPRC). The design of the converter was done theoreticaly and tested by using simulation program. The simulation and partial tests served to build prototype the Interleaves Converter (ILLC). The function of the converter was tested in laboratory. The laboratory results have been compared with the theoretical and the simulation results.