With the development of electric vehicle (EV) charging systems, energy storage systems (ESS), data center power supplies, and solid-state transformer (SST) systems, the fixed-ratio isolated DC-DC converter, namely the DC transformer (DCX), has gained significant popularity. Similar to the passive AC transformer, DCX can bidirectionally convey DC power with very high efficiency. Due to zero-voltage switching (ZVS) and a small root mean square (RMS) current, the open-loop CLLC resonant converter operating at the resonant frequency is a promising candidate for DCX with a constant voltage transfer ratio. In Chapter 2, to solve unsmooth bidirectional power flow and current distortion in the traditional CLLC-DCX with synchronization rectification (SR) modulation, a dual-active-synchronization (DAS) modulation is adopted with identical driving signals on both sides. First, the switching transition of this modulation is thoroughly analyzed considering the large switch's output capacitances. After comparing different transitions, a so-called sync-ZVS transition is more desirable with ZVS, has no deadtime conduction loss, and almost has load-independent voltage gain. An axis and center symmetric (ACS) method is proposed to achieve this switching transition. Based on this method, an overall design procedure of CLLC-DCX with DAS modulation is also proposed. However, designing a high-power and high-frequency transformer for CLLC-DCX presents significant challenges due to the trade-off between thermal management, leakage inductance minimization, and insulation requirements. To overcome this trade-off between power rating and operation frequency, a scalable electronic-embedded transformer (EET) with a low-voltage bridge integrated into the transformer windings is proposed in Chapter 3. The EET addresses the challenge through simple open-loop control and natural current sharing, enabling easy parallel connection and scaling to different power ratings. Based on this concept, a bidirectional, EET-based DC transformer (EET-DCX) is proposed to solve the transformer-level paralleling and resonant point shift issues in traditional LLC-DCX designs. By employing the embedded full bridge, the EET-DCX effectively cancels out the impedance of the leakage inductance, ensuring optimal operation at any frequency. Additionally, the EET-DCX retains the inherent advantages of the LLC-DCX, such as load-independent voltage gain, simple open-loop control, full-load range ZVS, and low circulating current. Leveraging these advantages, the proposed EET-DCX solution has the potential to push the boundaries of transformer performance to the MHz operation frequency range with hundreds of kilowatts of power capability. Moreover, to address the significant RMS current problem of the CLLC-DCX, a trapezoidal current modulation is also proposed in Chapter 3. Compared to the CLLC-DCX with a sinusoidal current, an EET-DCX with a trapezoidal current can reduce the total conduction loss by up to 23%. This total conduction loss includes semiconductor loss on both high-voltage and low-voltage bridges and transformer winding loss. In light of this EET concept, another resonant commutation (RC) EET-DCX is proposed to streamline the circuit. First, it replaces the embedded full bridge with a low-voltage bidirectional AC switch. Second, it introduces a resonant current commutation to realize a quasi-trapezoidal transformer current with a smaller RMS value. Compared to the triangular current produced by the original EET-DCX, the RMS current can be decreased by 15%. By incorporating only one embedded bidirectional AC switch, the high-frequency transformer leakage inductance impedance is fully neutralized. As a result, the rated power of the proposed RC EET-DCX can be readily scaled up through transformer-level parallelism. Furthermore, the RC EET-DCX maintains the benefits of a typical LLC/CLLC-DCX, including load-independent voltage gain, full load range ZVS, and low circulating current. However, either in EET-DCX or RC EET-DCX, the trapezoidal current modulation will increase the voltage stress on the low-voltage full bridge or bidirectional AC switch, especially when the leakage inductance is large and variable, such as in the high-power wireless charging application. To address this trade-off between RMS current and voltage stress, this paper proposes the concept of a hybrid resonant-type EET-DCX with a series resonant capacitor. Following this concept, two specific topologies, hybrid EET-DCX and hybrid RC EET-DCX, are proposed. The main difference between these topologies is that the former adopts a full bridge. In a hybrid RC EET-DCX, a resonant current commutation scheme is developed. Among these topologies, since the passive capacitor can mainly cancel the leakage inductance impedance, the full bridge or AC switch only needs to handle the remaining impedance. Thus, the voltage stress on active components can be dramatically decreased. Additionally, these two proposed topologies can retain all the advantages of previous EET-DCX designs, including natural current sharing, load-independent voltage gain, simple open-loop control, and full-load range ZVS. The comparison between these two topologies is thoroughly studied. Finally, a 12-kW DCX testbench is built to verify all the analysis and performance in Chapter 3. If output voltage regulation is required, DCX can cooperate with other voltage regulators to realize high conversion efficiency and power density. In Chapter 4, two DCX applications are implemented: an 18-kW 98.8% peak efficiency EV battery charger with partial power processing and a 50-kW symmetric 3-level buck-boost converter with common-mode (CM) noise reduction. In the first battery charger, a large portion of the power is handled by an 18 kW CLLC-DCX, and the remaining partial power goes through a 3-phase interleaved buck converter. The proposed switching transition optimization in Chapter 2 is adopted in the 18-kW CLLC-DCX to realize 98.8% peak efficiency. To handle the step-up and step-down cases at the same time, a symmetric 3-level buck-boost converter with coupled inductors is also studied as a post regulator. With symmetric topology and quadrangle current control, the converter can achieve a CM noise reduction and full load range ZVS with a small RMS current. To further optimize the performance and simplify the control, a mid-point bridging with a better CM noise reduction and a split capacitor voltage auto-balance is implemented. A 50-kW prototype is built to verify the above analysis. To summarize, Chapter 2 first proposes a switching transition optimization for CLLC-DCX. Later, to address the intrinsic trade-off between transformer rating power and frequency, an EET concept and its corresponding soft-switching DCX family are found in Chapter 3. Finally, to handle voltage regulation, two examples for practical applications are studied in Chapter 4 —one is an 18-kW partial power converter, and the other is a 50-kW 3-L buck-boost converter. Finally, Chapter 5 will draw conclusions and illustrate future work. / Doctor of Philosophy / With the development of electric vehicle (EV) charging systems, energy storage systems (ESS), data center power supply, and solid-state transformer (SST) systems, the fixed-ratio isolated dc-dc converter, namely dc transformer (DCX), has gained significant popularity. However, designing a high-performance DCX still has many challenges, such as large dead time loss, poor current sharing, and sensitivity to parameter tolerance. Firstly, the state-of-the-art resonant CLLC-DCX is optimized in Chapter 2. With an optimal switching frequency and dead time, both the primary and secondary sides of zero voltage switching (ZVS) can begin and finish simultaneously, which means dead time loss caused by current through the body diode can be eliminated. Therefore, the efficiency of CLLC-DCX can be improved. However, designing a high-power and high-frequency CLLC-DCX transformer still presents significant challenges due to the trade-off between thermal management, leakage inductance minimization, and insulation requirements. To overcome this trade-off, in Chapter 3, a scalable electronic-embedded transformer (EET) concept with a low-voltage bridge integrated into the transformer windings is proposed. The EET addresses the challenge through its simple open-loop control and natural current sharing, enabling easy parallel connection and scaling to different power ratings. In light of this EET concept, a new family of soft-switching DCXs is proposed for different applications, such as high-power wireless charging systems. All these EET-based DCXs retain the merits of typical CLLC-DCX, such as small circulating current ringing, small turn-off current, full load range ZVS, and load-independent gain. After realizing a desirable design for DCX, Chapter 4 presents two DCX applications with voltage regulation. Firstly, an 18 kW 98.8% peak efficiency battery charger is designed with partial power processing. Most of the power will go through an optimized DCX, and the remaining small portion of power will go through a 3-phase interleaved buck converter. On the other hand, DCX can also be adopted as a front-end or rear-end converter in a typical two-state DC-DC converter. As for another stage, a non-isolated DC-DC converter with a large output range can be used to handle voltage regulation. Following this structure, a 50-kW symmetric 3-L buck-boost converter with coupled inductors and reduced common emission is proposed. To summarize, the state-of-the-art CLLC-DCX is optimized in Chapter 2. Afterward, a new concept of EET-DCX and its corresponding DCX family is proposed in Chapter 3. After obtaining an optimized DCX, two practical applications with DCX are implemented in Chapter 4. Finally, Chapter 5 will draw conclusions and illustrate future work.

High step-down dc/dc converters are widely adopted in a variety of areas such as industrial, automotive, and telecommunication. The 48 V power delivery system becomes increasingly popular for powering high-current and low-voltage chips. The Series-Capacitor Buck (SCB) converter doubles the duty ratio and equalizes the current between the two phases. Hard switching has hindered efforts to reduce volume via increased switching frequency, although a monolithically integrated SCB converter has boosted current density. A Series-Resonator Buck (SRB) converter is realized by adding a resonant tank in series with the series capacitor Cs. All switches turn on at zero-voltage (ZVOn), and the low-side switches turn off at zero-current (ZCOff). The design of the SRB converter includes characterizing the design variables' impacts on the converter performances and designing low-loss resonant components as the series resonator. The Series-Resonator Buck converter belongs to the class of quasi-resonant converters. Its resonant frequency is higher than the switching frequency, and its waveforms are quasi-sinusoidal. This work develops a steady-state model of the SRB converter to calculate voltage gain, component peak voltages, and resonant inductor peak current. Each switching cycle is modeled based on the concept of generalized state-space averaging. The soft-switching condition of the high-side switches is derived. The ZVS condition depends on the normalized control variable and the load condition. The gain equation models the load-dependent characteristic and the peak gain boundary. The theoretical peak voltage gain of the SRB converter is smaller than the maximum gain of the SCB converter. A smaller normalized load condition results in a larger peak voltage gain of the SRB converter. The large-signal model of the SRB converter characterizes the low-frequency behavior of the low-pass filters with the series capacitor and the high-frequency behavior of the resonant elements. A design recommendation of t_off f_r<0.5 is suggested to avoid the oscillation between the series capacitor Cs and the output inductors Lo. In other words, the off-duration of the low-side switches is less than half of 1/fr, and therefore the negative damping effect from the parallel resonant tank to the vCs response is reduced. The transfer functions of the SRB converter are presented and compared with those of the SCB converter. The series resonator brings in an extra damping effect to the response of output capacitor voltage. The understanding of the analytical relationships among the resonant tank energy, voltage gain, and component stresses was utilized to guide the converter design of the converter's parameters. A normalized load condition at √2 minimizes the stresses of the series resonator by balancing the peak energy in the resonant elements Lr and Cr. The f_s variation with voltage gain M is less than 10%. The non-resonant components C_s, L_oa, and L_ob are designed according to the specified switching ripples. The ac winding loss complicates the winding design of a resonant inductor. This work replaces the rectangular window with a rhombic window to reduce the eddy current loss caused by the fringing effect. The window ratio k_y is added as a design variable. The impacts of the design variables on the inductance, core loss, and winding loss are discussed. The air-gap length l_g is designed to control the inductance. A larger k_y design results in a short inductor length l_c and a smaller winding loss. The disadvantages include a smaller energy density design and a larger core loss due to the smaller cross-sectional area. In the design example presented in the thesis, the presence of the rhombic shape increases the gap-to-winding distance by two times, and also reduces the y-component of the magnetic field by a factor of two. The total inductor loss is reduced by 56% compared to a conventional design with a rectangular winding window while keeping the same inductance and the same inductor volume. This dissertation implements a resonator, replacing the series capacitor, in an SCB converter. The resultant SRB converter shows a 30% reduction in loss and a 50% increase in power density. The root cause of the divergence issue is identified by modeling the negative damping effect caused by resonant elements. The presented transient design guideline clears the barriers to closed-loop regulation and commercialization of the SRB converter. This work also reshapes winding windows from rectangle to rhombus which is a low-cost change that reduces magnetic loss by half. The theoretical analysis and design procedures are demonstrated in a 200 W prototype with 7% peak efficiency increase compared to the commonly used 30 W commercial SCB product. / Doctor of Philosophy / High step-down dc/dc converters are widely adopted in a variety of areas such as industrial, automotive, and telecommunication areas. The 48 V power delivery system becomes increasingly popular for powering high-current and low-voltage chips. The Series-Capacitor Buck (SCB) converter doubles the duty ratio and equalizes the current between the two phases. Hard switching has hindered efforts to reduce volume via increased switching frequency although a monolithically integrated SCB converter has boosted current density. A Series-Resonator Buck (SRB) converter is realized by adding a resonant tank in series with the series capacitor Cs. All switches turn on at zero-voltage (ZVOn), and the low-side switches turn off at zero-current (ZCOff). The challenges to designing the SRB converter include characterizing the design variables' impacts on the converter performances and designing low-loss resonant components as the series resonator. The resultant SRB converter shows a 30% reduction in loss and a 50% increase in power density. The root cause of the divergence issue is identified by modeling the negative damping effect caused by the resonant elements. The presented transient design guideline clears the barriers of closed-loop regulation and commercialization of the SRB converter. This work also reshapes winding windows from rectangle to rhombus, which is a low-cost change that reduces magnetic loss by half. The theoretical analysis and design procedures are demonstrated in a 200 W prototype with 7% peak efficiency increase compared to the commonly used 30 W commercial SCB product.

This thesis describes the flexible voltage control of a multi-level-voltage-reinjection voltage source converter. The main purposes are to achieve reactive power generation flexibility when applied for HVdc transmission systems, reduce dynamic voltage balancing for direct series connected switches and an improvement of high power converter efficiency and reliability. Waveform shapes and the impact on ac harmonics caused by the modulation process are studied in detail. A configuration is proposed embracing concepts of multi level, soft-switching and harmonic cancellation. For the configuration, the firing sequence, waveform analysis, steady-state and dynamic performances and close-loop control strategies are presented. In order not to severely compromise the original advantages of the converter, the modulated waveforms are proposed based on the restrictions imposed mathematically by the harmonic cancellation concept and practically by the synthesis circuit complexity and high switching losses. The harmonic impact on the ac power system prompted by the modulation process is studied from idealistic and practical aspects. The circuit topology being proposed in this thesis is developed from a 12-pulse bridge and a converter used classically for inverting power from separated dc sources. Switching functions are deduced and current paths through the converter are analysed. Safe and steady-state operating regions of the converter are studied in phasor diagrams to facilitate the design of simple controllers for active power transfer and reactive power generations. An investigation into the application of this topology to the back-to-back VSC HVdc interconnection is preformed via EMTDC simulations.

Le projet industriel français MEGaN vise le développement de module de puissance à base de compostant HEMT en GaN. Une des application industrielle concerne l’aéronautique avec une forte contrainte en isolation galvanique (>100 kV/s) et en température ambiante (200°C). Le travail de thèse a été concentré sur une brique module de puissance (bras d’onduleur 650 V 30 A). L’objectif est d’atteindre un prototype de facteur de forme peu épais, 30 cm2 et embarquant l’ensemble des fonctions driver, alimentation de driver, la capacité de bus et capteur de courant phase. Cet objectif implique un fort rendement énergétique, et le respect de l’isolation galvanique alors que la contrainte en surface est forte. Le manuscrit, outre l’état de l’art relatif au module de puissance et notamment celui à base de transistor GaN HEMT, aborde une solution d’isolation de signaux de commande à base de micro-transformateur. Des prototypes de micro-transformateur ont été caractérisés et vieillis pendant 3000 H pour évaluer la robustesse de la solution. Les travaux ont contribué à la caractérisation de plusieurs composants GaN afin de mûrir des modèles pour la simulation circuit de topologie de convertisseur. Au sein du travail collaboratif MEGaN, notre contribution ne concernait pas la conception du circuit intégré (driver de grille), tout en ayant participé à la validation des spécifications, mais une stratégie d’alimentation du driver de grille. Une première proposition d’alimentation isolée pour le driver de grille a privilégié l’utilisation de composants GaN basse-tension. La topologie Flyback résonante avec clamp permet de tirer le meilleur parti de ces composants GaN mais pose la contrainte du transformateur de puissance. Plusieurs technologies pour la réalisation du transformateur ont été validées expérimentalement et notamment une proposition originale enfouissement du composant magnétique au sein d’un substrat polymère haute-température. En particulier, un procédé de fabrication peu onéreux permet d’obtenir un dispositif fiable (1000 H de cyclage entre - 55 ; + 200°C), avec un rendement intrinsèque de 88 % pour 2 W transférés. La capacité parasite d’isolation est réduite par rapport aux prototypes précédent. Deux prototypes d’alimentations à forte intégration utilisent soit les transistors GaN basse tension (2.4 MHz, 2 W, 74 %, 6 cm2), soit un circuit intégré dédié en technologie CMOS SOI, conçu pour l’application (1.2 MHz, 2 W, 77 %, 8.5 cm2). Le manuscrit propose par la suite une solution intégrable de mesure de courant de phase du bras de pont, basé sur une magnétorésistance. La comparaison expérimentale vis à vis d’une solution à résistance de shunt. Enfin, deux prototypes de convertisseur sont décrits, dont une a pu faire l’objet d’une validation expérimentale démontrant des pertes en commutation réduites. / The french industrial project MEGaN targets the development of power module based on GaN HEMT transistors. One of the industrial applications is the aeronautics field with a high-constraint on the galvanic isolation (>100 kV/s) and ambient temperature (200°C). The intent of this work is the power module block (3 phases inverter 650 V 30 A). The goal is to obtain a small footprint module, 30 cm2, with necessary functions such as gate driver, gate driver power supply, bulk capacitor and current phase sensor. This goal implies high efficiency as well as respect of the constraint of galvanic isolation with an optimized volume. This dissertation, besides the state of the art of power modules and especially the GaN HEMT ones, addressed a control signal isolation solution based on coreless transformers. Different prototypes based on coreless transformers were characterized and verified over 3000 hours in order to evaluate their robustness. The different studies realized the characterization of the different market available GaN HEMTs in order to mature a circuit simulation model for various converter topologies. In the collaborative work of the project, our contribution did not focus on the gate driver chip design even if experimental evaluation work was made, but a gate driver power supply strategy. The first gate driver isolated power supply design proposition focused on the low-voltage GaN HEMT conversion. The active-clamp Flyback topology allows to have the best trade-off between the GaN transistors and the isolation constraint of the transformer. Different transformer topolgies were experimentally performed and a novel PCB embedded transformer process was proposed with high-temperature capability. A lamination process was proposed for its cost-efficiency and for the reliability of the prototype (1000 H cycling test between - 55; + 200°C), with 88 % intrinsic efficiency. However, the transformer isolation capacitance was drastically reduced compared to the previous prototypes. 2 high-integrated gate driver power supply prototypes were designed with: GaN transistors (2.4 MHz, 2 W, 74 %, 6 cm2), and with a CMOS SOI dedicated chip (1.2 MHz, 2 W, 77 %, 8.5 cm2). In the last chapter, this dissertation presents an easily integrated solution for a phase current sensor based on the magnetoresistance component. The comparison between shunt resistor and magnetoresistance is experimentally performed. Finally, two inverter prototypes are presented, with one multi-level gate driver dedicated for GaN HEMT showing small switching loss performance.

The aim of this project is to describe, design and create a converter from 12V DC to 230 VRMS. The power of this device is about 500W. The device consists of two main converters. The first one is step-up DC/DC converter and the other is DC/AC inverter. Step-up converter is designed as a resonant converter. It is useful for pushing down losses in semiconductors and inceasing efficiency. The inverter is changing DC voltage from the first converter to AC voltage. Control of this device is realized with DSP Motorola. This device should be used mainly for supply common devices up to 500W. Main usage is planed in a car or to another place where is not posible to connect some device to plug.

Characterizing  power  switches  is  an  indispensable  step  when  designing  a  converter.  This  thesisinvestigates ways to achieve static and dynamic characterization of semiconductors for high power applications such as power grid or train traction. The static characterization has been tested with a Keysight B1506A device analyzer. The problems encountered have been analyzed and corrected.Then the design of a high current switching test bench for dynamic characterization is explained. The full-bridge  configuration  allows  controlled  and  spontaneous  commutations  so  the  bench  can measure hard and soft switching. The voltage can be up to 10 kV and the current up to 3 kA during the commutation. The choice of the probes is justified. The issues of bandwidth, input impedance and common mode current are taken into account. Data are processed in order to interpolate theswitching loss in hard and soft switching. / Karaktärisering  av  halvledarbrytare  är  ett  viktigt  steg  när  man  utformar  en  omvandlare.  Dennaavhandling undersöker olika sätt att uppnå statisk och dynamisk karakterisering av halvledare för högeffekttillämpningar såsom elnät eller ellok. Statisk karaktäriseringen har utförts med en Keysight B1506A-enhetsanalysator. De problem som uppstått har analyserats och korrigerats.Utformningen    av    en    testbänk    för    dynamisk    karakterisering    förklaras.    Den    kompletta bryggkonfigurationen möjliggör kontrollerad och spontan kommutation med spänningar upp till 10 kV och  strömmar  upp till 3 kA så att  bänken kan mäta hård  och mjuk  växling.  Valet  av sonderna förklaras.   Frågorna   om   bandbredd,   ingångsimpedans   och   common-mode   ström   tas   med   iberäkningen. Data bearbetas för att interpolera kopplings förlusten i hård och mjuk växling.