This dissertation is devoted to a unified and comprehensive study of zero-current-transition (ZCT) soft-switching techniques for high-power three-phase PWM inverter applications. Major efforts in this study are as follows: 1) Conception of one new ZCT scheme and one new ZCT topology; 2) Systematic comparison of a family of ZCT inverters; 3) Design, implementation and experimental evaluation of two 55-kW prototype inverters for electric vehicle (EV) motor drives that are developed based on the proposed ZCT concepts; and 4) Investigation of the ZCT concepts in megawatts high-frequency power conversions. The proposed ZCT techniques are also applicable to three-phase power-factor-correction (PFC) rectifiers. In order to minimize switching losses, this work first proposes a new control scheme for an existing three-phase ZCT inverter circuit that uses six auxiliary switches. The proposed scheme, called the six-switch ZV/ZCT, enables all main switches, diodes and auxiliary switches to be turned off under zero-current conditions, and in the meantime provides an opportunity to achieve zero-voltage turn-on for the main switches. Meanwhile, it requires no modification to normal PWM algorithms. Compared with existing ZCT schemes, the diode reverse-recovery current is reduced significantly, the switching turn-on loss is reduced by 50%, the resonant capacitor voltage stress is reduced by 30%, and the current and thermal stresses in the auxiliary switches are evenly distributed. However, a big drawback of the six-switch ZV/ZCT topology, as well as of other types of soft-switching topologies using six auxiliary switches, is the high cost and large space associated with the auxiliary switches. To overcome this drawback, this work further proposes a new three-phase ZCT inverter topology that uses only three auxiliary switches-- the three-switch ZCT. The significance of the proposed three-switch ZCT topology is that, among three-phase soft-switching inverters developed so far, this is the only one that uses fewer than six auxiliary switches and still has the following three features: 1) soft commutation for all main switches, diodes and auxiliary switches in all operation modes; 2) no modification to normal PWM algorithms; and 3) in practical implementations, no need for extra resonant current sensing, saturable cores, or snubbers to protect the auxiliary switches. The proposed six-switch ZV/ZCT and three-switch ZCT inverters, together with existing ZCT inverters, constitute a family of three-phase ZCT inverters. To explore the fundamental properties of these inverters, a systematic comparative study is conducted. A simplified equivalent circuit is developed to unify common traits of ZCT commutations. With the visual aid of state planes, the evolution of the family of ZCT inverters is examined, and their differences and connections are identified. Behaviors of individual inverters, including switching conditions, circulating energy, and device/component stresses, are compared. Based on the proposed six-switch ZV/ZCT and three-switch ZCT techniques, two 55-kW prototype inverters for EV traction motor drives have been built and tested to the full-power level with a closed-loop controlled induction motor dynamometer. The desired ZCT soft-switching features are realized together with motor drive functions. A research effort is carried out to develop a systematic and practical design methodology for the ZCT inverters, and an experimental evaluation of the ZCT techniques in the EV motor drive application is conducted. The design approach integrates system optimization with characterizations of the main IGBT device under the ZCT conditions, selection, testing and characterization of the auxiliary devices, design and selection of the resonant inductors and capacitors, inverter loss modeling and numerical analysis, system-level operation aspects, and layout and parasitic considerations. Different design aspects between these two ZCT inverters are compared and elaborated. The complexity of the 55-kW prototype implementations is compared as well. Efficiencies are measured and compared under a group of torque/speed points for typical EV drive cycles. Megawatts high-frequency power conversion is another potential application of the ZCT techniques. The integrated gate commutated thyristor (IGCT) device is tested and characterized under the proposed six-switch ZV/ZCT condition, and the test shows promising results in reducing switching losses and stresses. Improvements in the IGCT switching frequency and simplification of the cooling requirements under ZCT operations are discussed. In addition, a generalized ZCT cell concept is developed based on the proposed three-switch ZCT topology. This concept leads to the discovery of a family of simplified multilevel soft-switching inverters that reduce the number of auxiliary switches by half, and still maintain desirable features. / Ph. D.

This dissertation presents the systematic analysis and the critical assessment of the AC side soft-switching inverters in electric vehicle (EV) applications. Although numerous soft-switching inverter techniques were claimed to improve the inverter performance, compared with the conventional hard-switching inverter, there is the lack of comprehensive investigations of analyzing and evaluating the performance of soft-switching inverters. Starting with an efficiency comparison of a variety of the soft-switching inverters using analytical calculation, the dissertation first reveals the effects of the auxiliary circuit's operation and control on the loss reduction. Three types of soft-switching inverters realizing the zero-voltage-transition (ZVT) or zero-current-transition (ZCT) operation are identified to achieve high efficiency operation. Then one hard-switching inverter and the chosen soft-switching inverters are designed and implemented with the 55 kW power rating for the small duty EV application. The experimental evaluations on the dynamometer provide the accurate description of the performance of the soft-switching inverters in terms of the loss reductions, the electromagnetic interference (EMI) noise, the total harmonic distortion (THD) and the control complexity. An analysis of the harmonic distortion caused by short pulses is presented and a space vector modulation scheme is proposed to alleviate the effect. To effectively analyze the soft-switching inverters' performance, a simulation based electrical modeling methodology is developed. Not only it extends the EMI noise analysis to the higher frequency region, but also predicts the stress and the switching losses accurately. Three major modeling tasks are accomplished. First, to address the issues of complicated existing scheme, a new parameter extraction scheme is proposed to establish the physics-based IGBT model. Second, the impedance based measurement method is developed to derive the internal parasitic parameters of the half-bridge modules. Third, the finite element analysis software is used to develop the model for the laminated bus bar including the coupling effects of different phases. Experimental results from the single-leg operation and the three-phase inverter operation verify the effectiveness of the presented systematic electrical modeling approach. With the analytical tools verified by the testing results, the performance analysis is further extended to different power ratings and different bus voltage designs. / 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.

The work in this dissertation presents the first attempt in the literature to propose the concept of "soft switch". The goal of "soft switch" is to develop a standard PWM switch cell with built-in adaptive soft switching capabilities. Just like a regular switch, only one PWM signal is needed to drive the soft switch under soft switching condition. The core technique in soft switch development is a built-in adaptive soft switching circuit with minimized circulation energy. The necessity of minimizing circulation energy is first analyzed. The design and implementation of a universal controller for implementation of variable timing control to minimize circulation energy is presented. The controller has been tested successfully with three different soft switching inverters for electric vehicles application in the Partnership for a New Generation Vehicles (PNGV) project. To simplify the control, several methods to achieve soft switching with fixed timing control are proposed by analyzing a family of zero-voltage switching converters. The driver based soft switch concept was originated from development of a base driver circuit for current driven bipolar junction transistor (BJT). A new insulated-gate-bipolar-transistor (IGBT) and power metal-oxide-semiconductor field-effect-transistor (MOSFET) gated transistor (IMGT) base drive structure was initially proposed for a high power SiC BJT. The proposed base drive method drives SiC BJTs in a way similar to a Darlington transistor. With some modification, a new base driver structure can adaptively achieve zero voltage turn-on for BJT at all load current range with one single gate. The proposed gate driver based soft switching method is verified by experimental test with both Si and SiC BJT. The idea is then broadened for "soft switch" implementation. The whole soft switched BJT (SSBJT) structure behaves like a voltage-driven soft switch. The new structure has potentially inherent soft transition property with reduced stress and switching loss. The basic concept of the current driven soft switch is then extended to a voltage-driven device such as IGBT and MOSFET. The key feature and requirement of the soft switch is outlined. A new coupled inductor based soft switching cell is proposed. The proposed zero-voltage-transition (ZVT) cell serves as a good candidate for the development of soft switch. The "Equivalent Inductor" and state plane based analysis method are used to simply the analysis of coupled inductor based zero-voltage switching scheme. With the proposed analysis method, the operational property of the ZVT cell can be identified without solving complicated differential equations. Detailed analysis and design is proposed for a 3kW boost converter example. With the proposed soft switch design, the boost converter can achieve up to 98.9% efficiency over a wide operation range with a single gate drive. A high power inverter with coupled inductor scheme is also designed with simple control compared to the earlier implementation. A family of soft-switching converters using the proposed "soft switch" cell can be developed by replacing the conventional PWM switch with the proposed soft switch. / Ph. D.

Power conversion system design issues are expanding their role in information technology equipment design philosophies. These issues include not only improving power conversion efficiency, but also increased concerns regarding the cost and complexity of the power conversion design techniques utilized to satisfy the host system's total performance requirements. In particular, in computer system (personal computers, workstations, and servers) designs, the power "supplies" are rapidly becoming a limiting factor in meeting overall design objectives. This dissertation addresses the issue of simplifying the architecture of distributed power systems incorporated into computing equipment. In the dissertation's first half, the subject of the design of the distributed power system's front-end converter is investigated from the perspective of simplifying the conversion process while simultaneously improving efficiency. This is initially accomplished by simplifying the second-stage DC/DC converter in the standard two-stage front-end design (PFC followed by DC/DC conversion) through the incorporation of secondary-side control. Unique modifications are then made to two basic topologies (the flyback and boost converter topologies) that enable the two-stage front-end design to be reduced to an isolated PFC conversion stage, resulting in a front-end design that features reduced complexity and higher efficiency. In the dissertation's second half, the overall DC distributed power system design concept is simplified through the elimination of power processing conversion steps - the result being the creation of a high-frequency (HF) AC distributed power system. Design techniques for generating, distributing, and processing HF AC power in this new system are developed and experimentally verified. Also, an experimental comparison between both DC and AC distributed power systems is performed, illustrating in a succinct fashion the merits and limitations of both approaches. / Ph. D.

This dissertation presents voltage stabilization techniques for flying capacitors used in soft-switching multilevel active power filters. The proposed active filter has proved to be a solution for power system harmonics produced by static high power converters. However, voltage unbalance of the clamping capacitors in the active filter in practical applications was observed due to its unequal parameters. Thus, the fundamentals of flying capacitors were characterized dealing with voltage balancing between flying capacitors and dc capacitors under practical operation, rather than ideal conditions. The study of voltage balancing provides the fundamental high-level solutions to flying capacitor based multilevel converter and inverter applications without additional passive balancing circuits. The use of proposed voltage balancing techniques made it possible to have a simple structure for solving the problems associated with the conventional bulky passive resistors and capacitor banks. Furthermore, the proposed control algorithms can be implemented with a real time digital signal processor. It can achieve the high performance of the active filter by compensating an adaptive gain to the controller. The effectiveness of the proposed controller was confirmed through various simulations and experiments. The focus of this study is to identify and develop voltage stabilization techniques for flying capacitors used in a proposed active filter. The voltage unbalance is investigated and characterized to provide safe operations. After having defined the problems associated with the voltage unbalance, the most important voltage stabilization techniques are proposed to solve this problem, in conjunction with an instantaneous reactive power (IRP) control of an active filter. In order to reduce the switching losses and improve the efficiency of the active filter, the proposed soft-switching techniques were evaluated through simulation and experimentation. Experimental results indicate that the proposed active filter achieved zero-voltage conditions in all of the main switches and zero-current turn-off conditions to the auxiliary switches during commutation processes. Also, various studies on soft-switching techniques, multilevel inverters, control issues and dynamics of the proposed active filter are discussed and analyzed in depth. / Ph. D.

Isolated inverters feature the freedom in voltage step-up/down, electrical safety, and modularity. Among them, pseudo-dc-link inverters have the advantage of high efficiency due to their single-stage structure. Traditionally, pseudo-dc-link inverters are based on pulse-width-modulated converters, which suffer from hard switching, the need for auxiliary components, and/or high current stresses. Meanwhile, the series resonant converter has been prevalent in past decades due to its simplicity and high efficiency. Therefore, it is intriguing to design a single-stage inverter based on a series resonant converter. However, there are limited papers regarding such an inverter topology. To figure out the reason, basic modulation methods proposed or implied in the literature are summarized and evaluated through circuit simulation software. It turns out each basic modulation method has at least one critical drawback in modulation range, hard switching, and/or high current stresses. Given the deficiencies in the basic modulation methods, a hybrid modulation method is proposed here. The proposed method combines variable-frequency modulation in the high-output region and short pulse-density modulation in the low-output region. In this way, all the aforementioned critical drawbacks can be greatly alleviated. The hybrid modulation method is compared to the basic modulation methods based on three design metrics: the rms value of the resonant current, the magnetic flux of the transformer, and the turn-off current. By these design metrics that directly related to power losses, the benefit of the proposed method in terms of efficiency can be explained. Moreover, a power loss model is also established to provide more insights into the inverter's efficiency performance. It helps demonstrate how the selection of resonant tank and other factors affects the power loss distribution. Also, an inverter design procedure is introduced and a prototype is built to verify the proposed modulation method. The results show that the switching losses, especially the turn-on loss, can be well suppressed, and the losses in other passive components are well restrained. This implies the proposed method is suitable for high-frequency applications. Other than efficiency, output waveform quality is also important for an inverter. However, the changing plant model makes the controller design difficult. Therefore, a third-order model established by other researchers has been adopted to identify the pole locations. In addition, a gain-varying method is proposed for the compensator to reduce the gain variance caused by different operating conditions. The experimental results show that without the gain-varying method, the inverter may have issues in slow tracking and/or instability. Finally, in some scenarios, the inverter based on a series resonant converter can be regarded as a module. A multi-modular inverter can be formed by connecting the modules in an input-parallel-output-series configuration. In this case, a technique termed sequential waveform synthesis can be applied. The proposed technique can extend the region of variable-frequency modulation and shorten the region of short pulse-density modulation. This is beneficial to efficiency based on an analysis. With more than a certain amount of modules connected, the short pulse-density modulation can even be waived, which means the multi-modular inverter can be free from turn-on loss. In summary, this dissertation focuses on developing modulation methods for inverters based on the series resonant converter. Soft-switching feature and high efficiency are the two top priorities. The analytic and experimental results are provided based on standalone applications. / Doctor of Philosophy / Inverters are an important part of a modern electric power system, as they convert dc electric power into ac electric power. In some applications, inverters with electrical insulation (isolated inverters) are preferred due to the need for engineering freedom, safety, and other reasons. However, each conventional isolated inverter has some of the following drawbacks: hard-switching in semiconductor devices, high circulating current, poor transformer utilization, and high complexity. These drawbacks limit the efficiency and compactness of an inverter system, making the system less attractive to practical applications. An inverter based on a series resonant converter seems to be a solution because the series resonant converter is known for being simple and highly-efficient. However, there has yet to be a proper modulation method for it. Therefore, the main contribution of this dissertation is to propose a hybrid modulation method. With the proposed method, the inverter can operate with high efficiency. Furthermore, the hard-switching can be well suppressed, which means a high-frequency, compact design is possible. Besides the theory of the proposed method, this dissertation also includes a power loss model, a hardware design procedure, and analytic comparisons with other methods. In addition, a digital approach to control the inverter is proposed. Without it, the output voltage waveform may be highly distorted. Finally, another sequential control strategy is proposed in this dissertation for an integrated system. The integrated system is composed of multiple inverters based on a series resonant converter. With the sequential control strategy, the overall output waveform quality of the integrated system can be improved.

Wireless power transfer (WPT) with loosely coupled coils is a promising solution to deliver power to a battery in a variety of applications. Due to its convenience, wireless power transfer technology has become popular in consumer electronics. Thus far, the majority of the coupled coils in these systems are planar structure, and the magnetic field induced by the transmitter coil is in one direction, meaning that the energy power transfer capability degrades greatly when there is some angle misalignment between the coupled coils. To improve the charging flexibility, a three–dimensional (3D) coils structure is proposed to transfer energy in different directions. With appropriate modulation current flowing through each transmitter coil, the magnetic field rotates in different directions and covers all the directions in 3D space. With omnidirectional magnetic field, the charging platform can provide energy transfer in any direction; therefore, the angle alignment between the transmitter coil and receiver coil is no longer needed. Compensation networks are normally used to improve the power transfer capability of a WPT system with loosely coupled coils. The resonant circuits, formed by the loosely coupled coils and external compensation inductors or capacitors, are crucial in the converter design. In WPT system, the coupling coefficient between the transmitting coil and the receiving coil is subject to the receiver's positioning. The variable coupling condition is a big challenge to the resonant topology selection. The detailed requirements of the resonant converter in an omnidirectional WPT system are identified as follows: 1). coupling independent resonant frequency; 2). load independent output voltage; 3). load independent transmitter coil current; 4). maximum efficiency power transfer; 5). soft switching of active devices. A LCCL-LC resonant converter is derived to satisfy all of the five requirements. In consumer electronics applications, Megahertz (MHz) WPT systems are used to improve the charging spatial freedom. 6.78 MHz is selected as the system operation in AirFuel standard, a wireless charging standard for commercial electronics. The zero voltage switching (ZVS) operation of the switching devices is essential in reducing the switching loss and the switching related electromagnetic interference (EMI) issue in a MHz system; therefore, a comprehensive evaluation of ZVS condition in an omnidirectional WPT system is performed. And a design methodology of the LCCL-LC converter to achieve ZVS operation is proposed. The big hurdle of the WPT technology is the safety issue related to human exposure of electromagnetic fields (EMF). A double layer shield structure, including a magnetic layer and a conductive layer, is proposed in a three dimensional charging setup to reduce the stray magnetic field level. A parametric analysis of the double shield structure is conducted to improve the attenuation capability of the shielding structure. In an omnidirectional WPT system, the energy can be transferred in any direction; however the receiving devices has its preferred field direction based on its positioning and orientation. To focus power transfer towards targeted loads, a smart detection algorithm for identifying the positioning and orientation of receiver devices based on the input power information is presented. The system efficiency is further improved by a maximum efficiency point tracking function. A novel power flow control with a load combination strategy to charge multiple loads simultaneously is explained. The charging speed of the omnidirectional WPT system is greatly improved with proposed power flow control. / Doctor of Philosophy / Wireless power transfer (WPT) is a promising solution to deliver power to a battery in a variety of applications. Due to its convenience, wireless power transfer technology with loosely coupled coils has become popular in consumer electronics. In such system, the receiving coil embedded in the receiving device picks up magnetic field induced by the transmitter coil; therefore, energy is transferred through the magnetic field and contactless charging is achieved. Thus far, the majority of the coupled coils in these systems are planar structure, and the magnetic field induced by the transmitter coil is in one direction, meaning that the energy power transfer capability degrades greatly when there is some angle misalignment between the coupled coils. To improve the charging flexibility, a three–dimensional (3D) coils structure is proposed to transfer energy in different directions, also known as in omnidirectional manner. With omnidirectional magnetic field, the charging platform can provide energy transfer in any direction; therefore, the angle alignment between the transmitter coil and receiver coil is no longer needed. In a WPT system with loosely coupled coils, the energy transfer capability suffers from weak coupling condition. To improve the power transfer capability, the electrical resonance concept between the inductor and capacitor at the power transfer frequency is adopted. A novel compensation network is proposed to form a resonant tank with the loosely coupled coils and maximize the power transfer at the operating frequency. As for the WPT system with loosely coupled coils, the energy transfer capability is also proportional to the operating frequency. Therefore, Megahertz (MHz) WPT systems are used to improve the charging spatial freedom. 6.78 MHz is selected as the system operation in AirFuel standard, a wireless charging standard for commercial electronics. The zero voltage switching (ZVS) operation of the switching devices is essential in reducing the switching loss and the switching related electromagnetic interference (EMI) issue in a MHz system; therefore, a comprehensive evaluation of ZVS condition in an omnidirectional WPT system is performed. The big hurdle of the WPT technology is the safety concern related to human exposure of electromagnetic fields (EMF). Therefore, a double layer shield structure is first applied in a three dimensional charging setup to confine the electromagnetic fields effectively. The stray field level in our charging platform is well below the safety level required by the regulation agent. Although the energy can be transferred in an omnidirectional manner in the proposed charging platform, the energy should be directed to the target loads to avoid unnecessary energy waste. Therefore, a smart detection method is proposed to detect the receiver coil's orientation and focus the energy transfer to certain direction preferred by the receiver in the setup. The energy beaming strategy greatly improves the charging speed of the charging setup.

Three-phase rectifiers/inverters are widely used in grid-tied applications. Take the electric vehicle (EV) charging systems as an example. Within a certain space designated for the chargers, quick charging yet high efficiency are demanded. According to the current industry practice, with a power rating between 10 and 30 kW, the power density are limited by silicon (Si) power semiconductor devices, which make the systems operate at only up to around 30 kHz. The emerging wide bandgap (WBG) power semiconductor devices are considered as game changing devices to exceed the limits brought by their Si counterparts. Much higher switching frequency, higher power density and higher system efficiency are expected to be achieved with WBG power semiconductor devices. Among different types of WBG power semiconductor devices, Silicon Carbide Metal-Oxide-Semiconductor Field-Effect Transistors (SiC MOSFETs) are more popular in current research conducted for tens of kW power converter applications. However, the commonly adopted hard switching operation in this application still leads to significant switching loss at high frequency operation even for SiC-based systems. With the unique feature that the turn-off energy is almost negligible compared with the turn-on energy, critical conduction mode (CRM) based zero voltage soft switching turn-on operation is preferred for the SiC MOSFETs to eliminate the turn-on loss with small penalty on the conduction loss and on the turn-off loss. With this soft switching operation, switching frequency of SiC-based systems is able to be pushed to more than ten times higher than Si-based systems, and therefore higher power density yet even higher system efficiency can be achieved. The CRM-based soft switching is applied to three-phase rectifiers/inverters under the unity power factor operating condition first. Decoupled CRM-based control is enabled, and the inherent drawback of wide switching frequency variation range at CRM-based operation is overcome by the proposed novel modulation technique. It is the first time that CRM-based soft switching modulation is demonstrated in the most conventional three-phase H-bridge ac–dc converter, and more than three-time size reduction compared with current industry practice yet 99.0% peak efficiency are achieved at above 300 kHz switching frequency operation. Then this proposed soft switching modulation technique is extended to non-unity power factor operating conditions especially for grid-tied inverter system applications. With several improvements on the modulation, a generalized CRM-based soft switching modulation technique is proposed, which is applicable to both the unity and non-unity power factor conditions. With the power factor down to 0.8 lagging or leading according to commercial products, above 98.0% peak efficiency is achieved with the generalized soft switching modulation technique at above 300 kHz switching frequency operation. Furthermore from the aspect of electromagnetic interference (EMI), compared with the traditional Si-based design, CRM operation brings higher differential-mode (DM) EMI noise, and higher dv/dt with SiC MOSFETs brings higher common-mode (CM) EMI noise. What's more, hundreds of kHz switching frequency operation makes the main components of the system EMI spectrum located within the frequency range related to the EMI standard (150 kHz – 30 MHz). Therefore, several methods are adopted for the reduction of EMI noise. The total inductor current ripple is reduced with multi-channel interleaving control in order to reduce DM EMI noise. The balance technique is applied in order to reduce CM EMI noise. With PCB winding coupled inductors, the well-controlled parasitic parameters make the balance technique able to be effective for a uniform reduction of CM EMI noise from 150 kHz to above 20 MHz. In addition, PCB winding based magnetic designs are beneficial to achieving manufacture automation and reducing the labor cost. / Doctor of Philosophy / Power electronics and power conversion are crucial to many applications related to electricity, such as consumer electronics, domestic and commercial appliances, automobiles, data centers, utilities and infrastructure. In today's market, quality and reliability are usually considered as a given; high efficiency (low loss), high power density (small size and weight) and low cost are the main focuses in the design of power electronics products. In the past several decades, significant achievements in power electronics have been witnessed thanks to the silicon (Si) semiconductor technology, especially the Si power semiconductor devices. Nowadays, the development of Si power semiconductor devices is already close to the theoretical limits of the material itself. Therefore, in order to meet the increasing demands from customers in different applications, wide bandgap (WBG) based power semiconductor devices, namely Gallium Nitride (GaN) and Silicon Carbide (SiC), are becoming attractive because of its great potential compared with their Si counterparts. In literature, great contributions have already been made to understanding the WBG based power semiconductor devices. It is exciting and encouraging that some of the GaN-based power electronics products featuring high efficiency, high power density and low cost have been commercialized in consumer electronics applications. However, when pursuing these objectives, previous literature has not shown any applications of high frequency soft switching technology into the high power ac–dc conversion (usually three-phase ac–dc) in a simple way as the low power ac–dc conversion (usually single-phase ac–dc) in consumer electronics products. The key to achieving high efficiency, high power density and low cost is the high frequency soft switching operation. For single-phase ac–dc systems, the research on the realization of soft switching by control strategies instead of additional physical complexity has been intensively conducted, and this technology has also been adopted in the current industry practice. Therefore, the major achievement of this work is the development of a generalized soft switching control strategy for three-phase ac–dc systems, without adding any physical complexity, which is applicable to the simplest and most conventional three-phase ac-dc circuit topology. The proposed soft switching control strategy features bidirectional (rectifiers/inverters) power conversion, active/reactive power transfer, grid-tied/stand-alone modes, and scalability to multi-channel interleaved operation. Furthermore, with high frequency, the integration of magnetic components with embedded windings in the printed circuit board (PCB) becomes feasible, which is also beneficial to achieving electromagnetic compatibility (EMC) and manufacture automation. Based on the proposed control strategy and design methodology, a SiC-based 25-kW three-phase high frequency soft switching rectifier/inverter is developed for various applications such as electric vehicle (EV) charging stations, uninterruptible power supplies (UPS) and renewable energy based utilities.

The future power conversion system not only must meet the characteristics demanded by the load, but also have to achieve high power density with high efficiency, high ambient temperature, and high reliability. Density and efficiency are two key drivers and metrics for the advancement of power conversion technologies. Generally speaking, a high performance active device is the first force to push power density to meet the requirement of modern systems. Silicon has been a dominant material in power management since the late 1950s. However, due to continuous device optimizations and improvements in the production process, the material properties of silicon have increasingly become the limiting factor. Workarounds like the super junction stretch the limits but usually at substantial cost. The use of gallium nitride devices is gathering momentum, with a number of recent market introductions for a wide range of applications such as point-of-load (POL) converters, off-line switching power supplies, battery chargers and motor drives. GaN devices have a much lower gate charge and lower output capacitance than silicon MOSFETs and, therefore, are capable of operating at a switching frequency 10 times greater. This can significantly impact the power density of power converters, their form factor, and even current design and manufacturing practices. To realize the benefits of GaN devices resulting from significantly higher operating frequencies, a number of issues have to be addressed, such as converter topology, soft-switching technique, high frequency gate driver, high frequency magnetics, packaging, control, and thermal management. This work studies the insight switching characteristics of high-voltage GaN devices including some specific issues related to the cascode GaN. The package impact on the switching performance and device reliability will be illustrated in details. A stack-die package is proposed for cascode GaN devices to minimize the impact of package parasitic inductance on switching transition. Comparison of hard-switching and soft-switching operation is carried based on device model and experiments, which shows the necessity of soft-switching for GaN devices at high frequency. This work also addresses high dv/dt and di/dt related gate drive issues associated with the higher switching speed of GaN devices. Particularly, the conventional driving solution could fail on the high side switch in a half-bridge configuration due to relative large common-mode noise current. Two simple and effective driving methods are proposed to improve noise immunity and maintain high driving speed. Finally, this work illustrates the utilization of GaN in an emerging application, high density AC-DC adapter. Many design considerations are presented in detail. The GaN-based adapter is capable of operating at 1-2 MHz frequency with an improved efficiency up to 94%. Several design examples at different power levels, with a power density in the range of 20~35W/in3, which is a three-fold improvement over the state-of-the-art product, are successfully demonstrated. In conclusion, this work is focus on the characterization, and evaluation of GaN devices. Packaging, high frequency driving and soft-switching technique are addressed to fully explore the potential of GaN devices. High density adapters are demonstrated to show the advance of GaN device and its impact on system design. / Ph. D.