As a very special DC-DC converter, VRM (Voltage Regulator Module) design must follow the fast-developing trend of microprocessors. The design challenges are the high current, high di/dt, and stringent load-line requirement. When the energy is transferred from the input of a VRM, through the VRM, then through the power delivery path to the processor, it needs sufficient capacitors to relay this energy. The capacitors' number appears to be unrealistically large if we follow today's approach for the future processors. High frequency VRM with high control bandwidth can solve this problem, however, the degradation of efficiency makes the conventional buck converter and the hard-switching isolated topologies incapable of operating at higher frequency. The research goal is to develop novel means that can help a high-output- current VRM run efficiently at high frequency. A novel Complementary Controlled Bridge (CCB) self-driven concept is proposed. With the proposed self-driven scheme, the combination of the ZVS technique and the self-driven technique recycles the gate driving energy by making use of the input capacitor of the secondary- side synchronous rectifier (SR) as the snubber capacitor of the primary-side switches. Compared to the external driver, the proposed converter can save driving loss and synchronous rectifier body diode conduction loss. Additionally, compared to the existing level-shifted self-driven scheme for bridge-type symmetrical topologies, its gate signal ringing is small and suitable for high-frequency applications. Although the CCB self-driven VRM reduces the switching frequency-related losses significantly, the conduction loss is still high. Inspired by the current-doubler concept, a novel ZVS current-tripler DC-DC converter is proposed in this work. By utilizing more SR devices to share the current during the freewheeling period, the SR conduction loss is reduced. The current-tripler DC-DC converter has a delta/delta connected transformer that can be implemented with integrated magnetics. The transformer then becomes an integrated magnetic with distributed windings, which is preferred in high current applications. The current-tripler DC-DC converter in fact meets the requirements for the CCB self-driven scheme. The two concepts are then combined with an integrated gate drive transformer. The proposed CCB self-driven concept and current-tripler concept can both be applied to the 12V non-isolated VRMs. The proposed topology is basically a buck-derived soft-switching topology with duty cycle extension and SR device self-driven capabilities. Because there is no isolation requirement, the SR gate driving becomes so simple that the voltage at the complementary controlled bridge can be used to directly drive the SR gate. Both the gate driving loss and the SR body diode conduction loss are reduced. The proposed circuit achieves similar overall efficiency to a conventional 300kHz buck converter running at 1MHz. All the circuits proposed in this dissertation can use coupling inductors to improve both the steady-state efficiency and dynamic performances. The essence of the coupling inductors concept is to provide different equivalent inductances for the steady state and the transient. Moreover, when a current loop becomes necessary to achieve proper current sharing among phases, the current loop sample hold effect will make it difficult to push the bandwidth. The sample hold effect is alleviated by the coupling inductors concept. A small-signal model is proposed to study the system dynamic performance difference with different coupling inductor designs. As the verification, the coupling concept is applied to the 12V non-isolated CCB self-driven VRM and the bandwidth as high as one third of the switching frequency is achieved, which means a significant output capacitor reduction. / Ph. D.

The use of computers in the modern world has become prevalent in all aspects of life. The size of these machines has decreased dramatically while the capability has increased exponentially. A special DC-DC converter called a VRM (Voltage Regulator Module) is used to power these machines. The VRM faces the task of supplying high current and high di/dt to the microprocessor while maintaining a tight load regulation. As computers have advanced, so have the VRM's used to power them. Increasing the current and di/dt of the VRM to keep up with the increasing demands of the microprocessor does not come without a cost. To provide the increased di/dt, the VRM must use a higher number of capacitors to supply the transient energy. This is an undesirable solution because of the increased cost and real estate demands this would lead to in the future. Another solution to this problem is to increase the switching frequency and control bandwidth of the VRM. As the switching frequency increases the VRM is faced with efficiency and thermal problems. The current buck topologies suffer large drops in efficiency as the frequency increases from high switching losses. Resonant or soft switching topologies can provide a relief from the high switching loss for high frequency power conversion. One disadvantage of the resonant schemes is the increased conduction losses produced by the circulating energy required to produce soft switching. As the frequency rises, the additional conduction loss in the resonant schemes can be smaller than the switching loss encountered in the hard switched buck. The topology studied in this work is the 12V non-isolated ZVS self-driven presented in [1]. This scheme offered an increased efficiency over the state of the art industry design and also increased the switching frequency for capacitor reduction. The goal of this research was to study this topology and improve the magnetic design to decrease the cost while maintaining the superior performance. The magnetics used in resonant converters are very important to the success of the design. Often, the leakage inductance of the magnetics is used to control the ZVS or ZCS switching operation. This work presents a new improved magnetic solution for use in the 12V non-isolated ZVS self-driven scheme which increases circuit operation, flexibility, and production feasibility. The improved magnetic structure is simulated using 3D FEA verification and verified in hardware design. / Master of Science

In the early 1990's, with the boom of the Internet and the advancements in telecommunications, the demand for high-speed communications systems has reached every corner of the world in forms such as, phone exchanges, the internet servers, routers, and all other types of telecommunication systems. These communication systems demand more data computing, storage, and retrieval capabilities at higher speeds, these demands place a great strain on the power system. To lessen this strain, the existing power architecture must be optimized. With the arrival of the age of high speed and power hungry microprocessors, the point of load converter has become a necessity. The power delivery architecture has changed from a centralized distribution box delivering an entire system's power to a distributed architecture, in which a common DC bus voltage is distributed and further converted down at the point of load. Two common distributed bus voltages are 12 V for desktop computers and 48 V for telecommunications server applications. As industry strives to design more functionality into each circuit or motherboard, the area available for the point of load converter is continually decreasing. To meet industries demands of more power in smaller sizes power supply designers must increase the converter's switching frequencies. Unfortunately, as the converter switching frequency increases the efficiency is compromised. In particular, the switching, gate drive and body diode related losses proportionally increase with the switching frequency. This thesis introduces a loss saving self-driven method to drive the secondary side synchronous rectifiers. The loss saving self-driven method introduces two additional transformers that increase the overall footprint of the converter. Also, this thesis proposes a new magnetic integration method to eliminate the need for the two additional gate driver magnetic cores by allowing three discrete power signals to pass through one single magnetic structure. The magnetic integration reduces the overall converter footprint. / Master of Science

Denna rapport ar resultatet av ett kandidatexamensarbete som avlades på KTH under våren 2018 i maskinkonstruktion. Uppdragsgivare var KTH och Skogforsk; det svenska skogsbrukets forskningsinstitut, som är finansierat av skogsnäringen och den svenska staten. Bakgrunden till projektet är de ökande kraven på ekologi och ergonomi i branchen, samt bristen på förare och operatörer. Uppgiften var att förbereda en skotare, modellXt28, för automation modellbaserat. En skotare är ett terrängfordon som används för att transportera rundvirke, stubbar och liknande. Då arbetet för att helt automatisera ett fordon är väldigt omfattande begränsades detta projekt till att fokusera på skotarens perception av omgivningen. Läsaren kommer få ta del av utformningen av en skyddande sensorenhet, anpassad för den krävande miljön. Krav för automation av fordon, val av sensorer och placering av dessa, möjliga lastfall, och infästningsmöjligheter behandlas. En utmaning under arbetets gång har varit bristen på tillgängligt tidigare liknande arbete, där kombinationen autonomi och helt odefinierat körområde behandlades. / This report is the result of a bachelor thesis completed at KTH (Royal Institute of Technology, Stockholm, Sweden) during spring 2018 in machine design. The project was executed in collaboration with KTH and Skogforsk (the Forestry Research Institute of Sweden), which is the central research body for the Swedish forestry sector, and financed jointly by the government and the members of the institute. The background of the project is the ever increasing requirements of ecology and ergonomics in the business, and the shortage of operators. The object of the project was to prepare and adapt a forwarder developed by Skogforsk (among others), Xt28, for automation. A forwarder is a forestry vehicle used for transporting logs. As the process of fully automating a vehicle is very extensive this project was limited to focusing on the forwarder's perception of the surrounding environment. The reader will take part in the development of a protective sensor unit, fitted for the demanding environment of a forwarder in Sweden. Requirements for vehicle automation, suitable sensors and placement, possible load cases, and attachment possibilities will be considered. A challenge during the project was the lack of earlier work and projects found on the same area, where self driven vehicles and operation o road were both regarded.