Florida State University Libraries Electronic Theses, Treatises and Dissertations The Graduate School 2012 Interleaved Multi-Phase Isolated Bidirectional DC-DC Converter and Its Extension Zhan Wang Follow this and additional works at the FSU Digital Library. For more information, please contact lib-ir@fsu.edu THE FLORIDA STATE UNIVERSITY COLLEGE OF ENGINEERING INTERLEAVED MULTI-PHASE ISOLATED BIDIRECTIONAL DC-DC CONVERTER AND ITS EXTENSION By ZHAN WANG A Dissertation submitted to the Department of Electrical and Computer Engineering in partial fulfillment of the requirements for the degree of Doctor of Philosophy Degree Awarded: Summer Semester, 2012 Zhan Wang defended this dissertation on March 16, 2012. The members of the supervisory committee were: Hui Li Professor Directing Dissertation Anke Meyer-Baese University Representative Simon Y. Foo Committee Member Jim P. Zheng Committee Member Petru Andrei Committee Member The Graduate School has verified and approved the above-named committee members, and certifies that the dissertation has been approved in accordance with university requirements. ii To my parents: Guoliang Wang and Changhua Deng iii ACKNOWLEDGEMENTS First of all I want to thank my advisor, Dr. Hui Li, for giving me the opportunity to do my Ph. D program in Center for Advance Power Systems (CAPS) at FSU, providing me valuable ideas, suggestions on the field of power electronics. I also learned the rigorous attitude towards research and effective research skills from her, which will be useful for my future study and life. I am grateful to my committee: Dr. Simon Y. Foo, Dr. Jim P. Zheng, Dr. Petru Andrei and Dr. Anke Meyer-Baese for giving me their valuable advices and broadening my horizon on the research. I would also thank CAPS to provide me so convenient research environment, and thank the staff, scientists and technicians in CAPS for their support during my Ph.D study. Many thanks to our director, Dr. Steinar Dale, and Mr. Steve McClellan, Mr. Michael Coleman, Ms. Nancy Rainey, Ms. Joann Jirak, Mr. John Hauer, Mr. Steve Ranner, Mr. Ted Williams, Ms. Bianca Trociewitz, and Mr. Michael Sloan. I would thank my group colleagues, Dr. Liming Liu, Xiaohu Liu, Yan Zhou, Passinam Tatcho, Dr. Lei Wang, Dr. Haifeng Fan, Lei Wang and other students at CAPS, for their valuable suggestion, comments, discussions and support. Finally, I wish to express my sincere gratitude to my family for their love, support and understanding during hard times. iv TABLE OF CONTENTS List of Tables ................................................................................................................................ vii List of Figures .............................................................................................................................. viii Abstract ......................................................................................................................................... xii 1 INTRODUCTION ....................................................................................................................... 1 1.1 Research Background ........................................................................................................... 1 1.1.1 Electricity Vehicle Infrastructure with Energy Storage .............................................. 1 1.1.2 DC Distribution System with Renewable Energy Source ........................................... 2 1.2 Objective and Outline of the Research ................................................................................. 4 2 STATE-OF-THE-ART TECHNOLOGY .................................................................................... 6 2.1 Bidirectional DC-DC Converters.......................................................................................... 6 2.1.1 Buck-boost Half Bridge DC-DC Converters............................................................... 6 2.1.2 Dual Active Bridge DC-DC Converters ...................................................................... 7 2.1.3 Current-fed full-bridge bidirectional DC-DC Converter............................................. 8 2.1.4 Current-fed Boost Dual-half-bridge (DHB) Bidirectional Converter ....................... 10 2.2 Multiphase Interleaved DC-DC Converter ......................................................................... 10 2.3 Multi-port DC-DC Converters ............................................................................................ 11 2.4 The Proposed Three-phase DAB Bidirectional DC-DC Converter .................................... 13 3 THREE-PHASE TWO-PORT DUAL-ACTIVE-BRIDGE (DAB) DC-DC CONVERTER .... 14 3.1 Introduction ......................................................................................................................... 14 3.2 The Proposed Topology and Comparison .......................................................................... 16 3.2.1 Topology Description ................................................................................................ 16 3.2.2 Operating Mode Analysis .......................................................................................... 18 3.2.2.1 50% Fixed duty cycle .................................................................................... 18 3.2.2.2 Varied duty cycle........................................................................................... 23 3.3 Analysis of ZVS Conditions ............................................................................................... 28 3.3.1 ZVS Conditions for Voltage Source DAB3 Converter ............................................. 28 3.3.2 ZVS Conditions for Current-fed DAB3 Converter ................................................... 29 3.4 Analysis of Unbalance Issue ............................................................................................... 33 3.4.1 Analysis of Current Unbalance ................................................................................. 33 3.4.2 Current Sharing Control ............................................................................................ 37 v 3.5 Converter Design Guideline ............................................................................................... 43 3.5.1 Transformer Design ................................................................................................... 43 3.5.2 DC Inductor Design................................................................................................... 45 3.5.3 Power Loss Analysis ................................................................................................. 46 3.6 Control Strategies for Current-fed Topology...................................................................... 51 3.6.1 Small Signal Modeling .............................................................................................. 51 3.6.2 Control system design ............................................................................................... 55 3.7 Experimental Results .......................................................................................................... 56 3.8 Summary ............................................................................................................................. 62 4 INTEGRATED THREE-PORT THREE-PHASE DAB DC-DC CONVERTER ..................... 64 4.1 Introduction ......................................................................................................................... 64 4.2 Converter Description ......................................................................................................... 67 4.3 ZVS Conditions Analysis ................................................................................................... 71 4.3.1 Pseudo two-port ZVS Analysis ................................................................................. 72 4.3.2 ZVS conditions in three-port mode ........................................................................... 74 4.3.3 ZVS Conditions in General ....................................................................................... 76 4.4 Control System Design ....................................................................................................... 78 4.5 Experimental Results .......................................................................................................... 85 4.6 Summary ............................................................................................................................. 90 5 CONCLUSION AND FUTURE WORK .................................................................................. 91 5.1 Conclusions ......................................................................................................................... 91 5.2 Future work ......................................................................................................................... 92 REFERENCES ............................................................................................................................. 93 BIOGRAPHICAL SKETCH ...................................................................................................... 104 vi LIST OF TABLES 3.1 ΔI/Iavg resulting from unbalanced leakage inductance ...........................................................37 3.2 The relationship between regulation of φ and ΔI/Iavg ............................................................39 3.3 Leakage inductance of each phase (refer to LVS) .................................................................44 3.4 Specifications and parameters of converter..............................................................................56 4.1 Operation modes in terms of different power flow ...............................................................70 4.2 ZVS Conditions in Different Operation ................................................................................78 4.3 Three-port Converter Parameters ..........................................................................................80 4.4 Parameters of PV panel Sunpower 215 (25◦C, 1000W/m2) ..................................................85 vii LIST OF FIGURES 1.1 Fuel Cell Electric Vehicle Power Train with Energy Storage .................................................2 1.2 PV residential complex in DC distribution system .................................................................3 2.1 Single phase buck-boost converter ..........................................................................................6 2.2 Three-phase buck-boost converter ..........................................................................................7 2.3 Full bridge dual-active-bridge (DAB) bidirectional converter ................................................8 2.4 Dual-half-bridge (DHB) bidirectional converter .....................................................................8 2.5 Current-fed full bridge bidirectional converter .......................................................................9 2.6 Current-fed boost dual-half-bridge bidirectional converter ....................................................9 2.7 Three-phase dual-active-bridge bidirectional dc-dc converter ..............................................11 2.8 Three-phase six-leg dc-dc converter .....................................................................................11 2.9 Tri-mode half-bridge converter .............................................................................................12 2.10 Three-port bidirectional dc-dc converter ...............................................................................12 3.1 Proposed three-phase current-fed dual-active-bridge bidirectional DC-DC converter .........16 3.2 Voltage and current waveforms in transformer and DC input inductor: (a) φ ≤ π/3; (b) π/3 < φ < 2π/3; .........................................................................................................................................17 3.3 Comparison of Power and power factor for DAB3 and 3DHB converters ...........................21 3.4 Comparison of power and power factor for DAB3 and 3DHB converters ...........................22 3.5 Six operating areas with different (D, φ) and corresponding transformer current waveforms ...............................................................................................................................................24 3.6 Power flow versus duty cycle D and phase shift angle φ ......................................................24 3.7 Power flow of DAB3 and 3DHB converter with different (D, φ) .........................................25 3.8 PF of DAB3 and 3DHB converter with different (D, φ) .....................................................26 3.9 Comparison of PF of DAB3 and 3DHB converter with different (D, φ) ..............................27 viii 3.10 RMS current curves on LVS MOSFETs ...............................................................................28 3.11 ZVS boundaries and power curves at different D: (a) D = 1/3, 2/3; (b) D = ½ ....................30 3.12 The middle points of one leg on LVS and HVS ....................................................................31 3.13 DC inductor current in one switching period ........................................................................31 3.14 ZVS boundaries under different m ........................................................................................32 3.15 Transformation between Y-model to Δ-model ......................................................................33 3.16 Four Transformer connection types DC-DC converter: (a) Y-Y DAB3; (b) 3DHB; (c) Δ-Δ DAB3 with integrated Ls; (d) Δ-Δ DAB3 with external Ls ............................................................35 3.17 Phasor diagram of phase voltage and current ........................................................................36 3.18 Flow chart of ratio presetting current sharing control ...........................................................40 3.19 Phase current and transformer current waveforms without unbalance controller: (a) Splitcap type; (b) Y-Y type; (c) Δ- Δ type ............................................................................................41 3.20 Phase current and transformer current waveforms with unbalance controller: (a) Split-cap type; (b) Y-Y type; (c) Δ- Δ type ...................................................................................................42 3.21 The sectional view of transformer .........................................................................................43 3.22 Input current ripple versus duty cycle ...................................................................................45 3.23 Total winding copper loss ratio versus ξ and number of layers M ........................................49 3.24 Ploss distribution in different output power in different D .....................................................50 3.25 Total Ploss curves in different D .............................................................................................50 3.26 Equivalent circuit of average model ......................................................................................51 3.27 Equivalent small signal circuit model ...................................................................................52 3.28 Bode plots of control to output ..............................................................................................54 3.29 Bode plots of voltage loop gain with compensator ...............................................................55 3.30 Photo of 6kW experimental prototype ..................................................................................57 3.31 System control system including current sharing controller .................................................57 ix 3.32 Three-phase inductor current and total input current: (a) Idc at D = 1/3, (b) Idc at D = 1/2, (c) Idc at D = 2/3...................................................................................................................................59 3.33 Transformer current on secondary side with different D: (a) D = 1/3; (b) D = 1/2; (c) D = 2/3 ...............................................................................................................................................60 3.34 ZVS waveforms for Sa1 and Sa2 at Po=1200W in (a) Vin=24V; (b) Vin=36V; (c)Vin=48V ....61 3.35 Voltage and current waveforms when Vin varies between 24V and 48V ..............................62 3.36 Measured efficiency of proposed converter at Vin = 24V, 36V and 48V...............................62 4.1 A DC distribution system with basic cell for PV applications: Energy sources, Energy storage and Load ............................................................................................................................66 4.2 Three-port integrated bi-directional dc-dc converter ............................................................68 4.3 Six operation areas with different duty cycle and phase-shift angle, and shadowed part is the practical operating area ............................................................................................................69 4.4 Operation modes in different power flow. (A) P1>0, P2<0, P3<0; (B) P1>0, P2>0, P3<0; (C) P1>0, P2<0, P3>0; (D) P1=0, P2<0, P3>0; (E) P1=0, P2>0, P3<0; ...................................................69 4.5 Battery’s voltage in charge/discharge performance ..............................................................73 4.6 ZVS boundaries in pseudo “two-port” mode ........................................................................74 4.7 The key current waveforms in different operation modes .....................................................76 4.8 The equivalent circuit of three-port dc-dc converter .............................................................79 4.9 Control system diagram .........................................................................................................79 4.10 Current open loop gain of DAB3 stage built in the laboratory .............................................81 4.11 Average model of three-port dc-dc converter .......................................................................82 4.12 Simulation results comparison: 1, Circuit model; 2, Equivalent circuit model; 3, Average model..............................................................................................................................................82 4.13 One day simulation results using average model ..................................................................84 4.14 Discharge performance of one battery module .....................................................................86 4.15 Charge performance of one battery module ..........................................................................86 x 4.16 Experimental set up ...............................................................................................................87 4.17 V-I characteristics curve for five PV panels in parallel ........................................................87 4.18 One day scale down experimental results .............................................................................88 4.19 ZVS waveforms of Sa2 in different operating modes: (a) mode B; (b) mode C; (c) mode E .... ...............................................................................................................................................89 xi ABSTRACT Recently, along with the development of renewable energy technology and threat of energy shortage, hybrid electric vehicles (HEV) and DC microgrid system are increasingly attracting attentions in industry and academia. By combining internal combustion engine (ICE) and high-performance energy storage such as battery, fuel-cell and ultracapacitors, HEVs can achieve twice the fuel economy of conventional vehicles. DC microgrid is an appropriate system to interconnect dc energy sources and to supply high quality power. To enable the usage of dc energy storage, developing power converters as the power electronics interface of dc energy sources becomes imminent. Currently, the voltage type bidirectional converter is dominating topology in dc-dc applications, which is not suitable for renewable energy source with wide voltage range. Although some current type converters have been proposed, most of them are dealing with unidirectional or low power system. For a high power energy storage system, high voltage conversion ratios, high input currents and wide input voltage range are the major barriers to achieving high-efficiency power conversions. This thesis proposes a novel three-phase currentfed dual-active-bridge (DAB) dc-dc converter with transformer isolation to overcome these obstacles. The major features of the proposed converter are the following: (1) Increase converter power rating by paralleling phases; (2) Reduce the size of input dc inductors and dc link capacitor with interleaved control; (3) Achieve Zero-Voltage Switching (ZVS) over a wide load range and wide input voltage rage without auxiliary circuitry; High conversion efficiency above 94% is verified with wide input voltage range. The detailed operation analysis and experimental results to prove the proposed converter are given in chapter 3. For integrating primary sources and energy storage, this thesis also proposes an integrated three-port bidirectional dc-dc converter based on three-phase current-fed DAB converter. Comparing to the individual dc-dc converters, the major advantages of the proposed integrated three-port converter include: (1) Higher power density due to multiport and multiphase interleaved structure; (2) Easier implementation of centralized control; (3) Decoupled power management control due to natural decoupled control variables; (4) Zero voltage switching in different operation mode. Comparing to two-port dc-dc converter, there are much more operation modes for integrated three-port dc-dc converter. Based on the integrated three-port converter, a xii photovoltaic (PV) system with battery backup is discussed. PV panel with wide voltage variation is connected to the current-fed port and battery as an energy storage with small voltage variation is connected to the dc link. By controlling the phase shift angle, the power exchange can be controlled between low voltage side (LVS) and high voltage side (HVS). By controlling the duty cycle, the PV can realize maximum power point tracking control (MPPT). The battery as an energy buffer is charging or discharging to wipe off the gap between generated power and required power. For the grid-connected mode, it is also helpful to manage the SOC of battery. The detailed analysis, simulation and experimental verification are provided in chapter 4. Finally, the last chapter concludes the previous work and gives the scope of the future work. xiii CHAPTER ONE 1 INTRODUCTION 1.1 Research Background 1.1.1 Electricity Vehicle Infrastructure with Energy Storage Global warming is becoming the most complicated and important issue facing the human being in this century. The surface temperature of the earth has increased by about 1 ºF over the past 100 years [1]. The global warming is mainly caused by the greenhouse gases emission. The greenhouse effect also results in climate change. In United States, the main source of greenhouse gases emissions is fossil fuel combustion, which provides around 85% of national energy supply [2]. According to DOE 2009 report [3], transportation will deplete around 70% of total oil usage. Abundant exhaust gases emission will also result in a series of environment issues. Under this background, advanced pure electric vehicles and hybrid vehicles are developed in many vehicle companies and research institutes. Mass-produced hybrid electric vehicles have been introduced worldwide such as Toyota Prius, Nissan Leaf and Chevrolet Volt, etc. High performance batteries as main power source together with Internal Combustion Engine (ICE) together are installed in hybrid cars, thus the efficiency being remarkably improved. The bidirectional dc-dc converters as the key components in future electric cars are paid attention in the field of power electronics. Many topologies and system structures are addressed to improve the efficiency and system performance. To integrate 14V and 42V dc source on the vehicle, a three-port isolated bidirectional dc-dc converter was proposed [4]. In order to improve the dynamic characteristic, battery with high energy density and supercapacitor with high power density were used and interfaced using a three-port dc-dc converter at the same time [5, 6]. The fuel cell and battery hybrid vehicle is also a promising solution for the future vehicle because of it zero emission and fast dynamic performance. The battery is connected to the dc-link through a bidirectional dc-dc converter so it is easy to control the power flow of system and improve the life cycle of battery. Fig. 1 gives a Fuel Cell electric vehicle drive train. The main power is provided by fuel cell through unidirectional DC-DC converter. The battery and ultracapacitor are interfaced to DC bus as auxiliary energy source to improve dynamic performance and absorb the braking regenerated energy. Normally, the battery in vehicle also provides power to some accessory device such as 1 CD player, air-conditioner and power steering system. For safety concern, the voltage of battery and ultracapacitor are lower than human safe voltage, so the isolated transformers between low voltage energy storage and high voltage dc bus are needed. So the dc-dc converter to interface battery and ultracapacitors should have such characteristics: 1, Bidirectional power flow capability; 2, high power density so as to reduce the converter size; 3, high efficiency under wide input voltage range. DC Bus 300~500V Fuel Cell DC/DC Converter Traction Inverter Battery Traction Motor Bidirectional DC/DC Converter Ultra capacitor Bidirectional DC/DC Converter Fig. 1.1 Fuel Cell Electric Vehicle Power Train with Energy Storage 1.1.2 DC Distribution System with Renewable Energy Source With the application of renewable energy in residential utility system, DC microgrid [7 9] as a new utility grid for local power generation has been developed. The conventional electrical system in place today sees our electrical devices powered by AC mains. But as renewable technologies such as solar photovoltaics and wind power become more prevalent at a household level, DC microgrids could be a cheaper and more efficient alternative. Renewable 2 energy source such as fuel cells and many small scale sustainable energy sources generate low voltage DC power. The small DC power sources send power to AC utility grid, thus requiring costly and inefficient DC/AC inverters, and even the power may ultimately be utilized by a DC device such as personal computer, TV and LED lighting, etc. A possible solution is to install a DC microgrid linking DC power supplies to DC devices. The renewable energy sources generate power and send to a DC bus to interface the DC load and energy storage system. There is no DC/AC/DC conversion between DC load and DC power supplies, thus reducing the power loss and simplifying the system. Utility Grid AC DC AC/DC DC Bus ... DC/DC DC/DC DC/DC DC/DC DC Load ESS PV DC Load ESS PV ... DC/DC DC/DC DC Load ESS PV Fig. 1.2 PV residential complex in DC distribution system Fig. 2 shows a PV residential DC microgrid system with energy storage. The power generated by PV panel supports local DC load, and the ESS as an energy buffer balances the power between PV and load. The common DC bus is connected to an AC utility grid through inverter, so that utility grid can provide power to the residential and in some conditions the excessive power from PV can send to the AC grid. DC-DC converters are applied in microgrid 3 system to interface the DG and ESS. So the converter should meet the following requirement: 1, Bidirectional function to charge and discharge ESS; 2, Maximum power point tracking function so as to utilize the power from DG as much as possible; 3, Multiport topology to interface with multiple DG (PV and DC wind turbine) and ESS (Battery and Ultracapacitor) to reduce the count of DC-DC converter. 1.2 Objective and Outline of the Research Based on the applications discussed above, the first main objective is to develop a bidirectional isolated dc-dc converter. A three-phase bidirectional current-fed dc-dc converter is proposed as the interface converter between low voltage ESS and high voltage load. Three phase dual active bridge is first proposed by [10] for high power high power density applications. With the advantages of bidirectional, natural soft-switching and interleaving features, DAB converters are widely studied and applied in power electronics and power system fields. Several types of bidirectional DC-DC converters were derived from DAB converter to satisfy specific requirement [11 - 13]. In [11], a current-fed full-bridge bidirectional dc-dc converter was proposed to reduce the switching loss and increase voltage transfer ratio. In [13], a current-fed dual half bridge was addressed for the minimum device counts and total device rating (TDR) approach. The converter can also operate in phase shift angle plus duty cycle control mode so as to handle with varied input voltage. Using this topology, [14] and [15] developed different three-port dc-dc converter for vehicle applications. Combined with three-phase DAB converter with current-fed DHB converter, a threephase current-fed DAB converter is proposed for high power and high power density application. In this project, we try to realize the following targets. Realization of high efficiency under wide voltage range. The devices can be soft- switched if the dc link voltages on both sides are matched, and the switching loss and reactive power loss will be low in this operating condition. Detailed operation mode and ZVS conditions analysis on current-fed DAB3 converter. In order to keep the dc link voltage constant, phase shift + duty cycle control is applied and the operating modes will be more complex than phase shift control method. The operating modes should be clarified for hardware and controller design. 4 Based on the principle analysis, 6kW dc-dc converter will be developed and hardware design and optimization guideline are also studied. The second main objective is to develop a PV grid interactive system using current-fed DAB3 as a three-port bidirectional dc-dc converter to interface with PV panels, energy storage and DC bus. In this three-port PV grid interactive system, the following topics will be reached. Analysis on power flow control and power management. Using a three-port DAB3 converter, the power flow can be controlled bidirectional by phase shift angle tuning. The PV panel can realize maximum power point tracking (MPPT) control by controlling duty cycle. The charging or discharging ESS is depending on the power difference between that generated by PV and that consumed by load and grid. Optimization of energy source sizing for PV residential system. How to design ESS and PV size is also a crucial object in the application. Based on the specific household renewable energy system, we try to design and optimize the ESS and PV volume for better economics and efficiency. 5 CHAPTER TWO 2 STATE-OF-THE-ART TECHNOLOGY 2.1 Bidirectional DC-DC Converters 2.1.1 Buck-boost Half Bridge DC-DC Converters Fig. 2.1 gives a simple buck-boost bidirectional converter. This simple topology is widely applied because it can meet the requirement to interface with different energy storage [1 - 4]. It can realize bidirectional power flow and high efficiency because of small counts of components. The topology can extend to multiphase interleaved structure for high power application and smaller passive components. Fig. 2.2 shows a three-phase bidirectional buck-boost converter [5]. The size of inductors and capacitor are significantly reduced comparing with single phase topology, but the current ripple is also reduced. i2 Sa1 i1 Ldc C1 VL Sa2 Fig. 2.1 Single phase buck-boost converter 6 VH i2 Sa1 ia ib ic Sc1 Sb1 Ldc1 Ldc2 Ldc3 C1 VH VL Sa2 Sc2 Sb2 Fig. 2.2 Three-phase buck-boost converter 2.1.2 Dual Active Bridge DC-DC Converters Buck-boost bidirectional converter can interface with the different energy sources if their voltage ratings are close. In some cases, the converters with large turns ration isolated transformers are used for the reason that the voltage ratings have a tremendous difference between different energy source and electrical isolation is necessary for safety concern. So far, there are many galvanically isolated high power bidirectional dc-dc converter topologies, and the dual active bridge (DAB) dc-dc converter [6] are most frequently reported and studied in [7 - 10] because of its merits such as bidirectional power flow, buck-boost operation and zero voltage switching operation without additional components. The DAB converter was first proposed in [6], and Fig. 2.3 shows the full bridge topology. The converter utilizes the leakage inductance of the isolated transformer as the main energy storage element and the direction and magnitude of power flow is controlled by phase shift angle between the voltage exerted on the LVS and HVS of transformer. Fig. 2.4 shows a dual-halfbridge dc-dc converter [11] which is suitable to high voltage, low current fields due to the lower transformer core loss. Moreover DHB has only half of the number of switching devices as DAB so that it is a good selection for cascaded modules structure. 7 LVS i1 Sa1 Sb1 a Sr1 isa 1 : N ir VL Ss1 c b C1 Sa2 i2 HVS Sb2 Sr2 C2 is VH d Ss2 Figure 2.3 Full bridge dual-active-bridge (DAB) bidirectional converter i1 LVS Sa1 HVS C1 iLs C3 Ls i2 Sr1 1 : N ir VL VH C2 C4 Sr2 Sa2 Figure 2.4 Dual-half-bridge (DHB) bidirectional converter 2.1.3 Current-fed full-bridge bidirectional DC-DC Converter A current-fed full-bridge bidirectional dc-dc converter [12 - 13] shown in Fig. 2.5 was proposed to reduce switching loss and increase the voltage transfer ratio. The converter can operate in boost-mode and buck-mode. A simple clamp circuit consisted of an active switch and a capacitor is used on the current-fed side to achieve soft-switching operation in both modes. In buck mode, the converter can achieve hybrid zero-voltage and zero-current switching (ZVZCS) 8 for voltage-fed side switches and the switches on current-fed side operate in synchronous rectified mode to reduce the conduction loss. In boost mode, the converter achieves ZVS for current-fed side switches and the switches on voltage-fed side operated in synchronous rectified mode. High efficiency under wide voltage range can be obtained in this topology. Since the modulation methods for buck mode and boost mode are different, the control strategy will be complex. LVS Lin Sa1 Sb1 a Sa Sr1 isa Ls 1 : N is b C1 Sa2 Sb2 Ss1 c ir VL i2 HVS C2 VH d Ss2 Sr2 Figure 2.5 Current-fed full bridge bidirectional converter LVS Sa1 iLs HVS C1 Ls C3 i2 Sr1 1 : N ir i1 Ldc VH VL C2 C4 Sr2 Sa2 Figure 2.6 Current-fed boost dual-half-bridge bidirectional converter 9 2.1.4 Current-fed Boost Dual-half-bridge (DHB) Bidirectional Converter Fig. 2.6 shows a current-fed boost DHB converter [14]. Combined the boost converter with dual-half-bridge, a current-fed boost dual-half-bridge (DHB) converter is proposed in some literatures. Similar to the DAB converter, the power flow is also controlled by phase shift angle between the transformer voltage on LVS side and HVS side. The current-fed side voltage can be boosted by duty cycle control and make the voltage on both sides to be matched so as to implement soft-switching operation. 2.2 Multiphase Interleaved DC-DC Converter For high-power-density high-power applications, multiphase interleaved soft-switching dc-dc converters are promising topologies because of smaller passive components and conduction loss. Fig. 2.7 shows a three-phase DAB bidirectional dc-dc converter [6, 15] in which the power flow is controlled by phase shift angle. In some literatures, the topology operated in different duty cycle is discussed. The high efficiency and high power density is verified in the experiment. For the unidirectional application, Fig. 2.8 provides another three-phase interleaved topology. The power rating is increased by paralleling phases, and output voltage is doubled by transformer Δ-Y connection, thus lowering the transformer turns ratio. Moreover, the circuit operates in ZVZCS over a wide load range without auxiliary circuitry. But the disadvantage is doubled count of switching devices. 10 i1 LVS Sa1 Sc1 Sb1 a VL C1 c St1 r Ls2 Ls3 n C2 s m VH t Sc2 Sb2 Sa2 Ss1 Sr1 Ls1 b i2 HVS 1 : N Ss2 Sr2 St2 Figure 2.7 Three-phase dual-active-bridge bidirectional dc-dc converter i1 LVS Sa1 Sb1 Sc1 Sr1 Ss1 St1 1 : N Vin C2 Vo C1 Sa2 Sb2 Sc2 Sr2 St2 Ss2 Figure 2.8 Three-phase six-leg dc-dc converter 2.3 Multi-port DC-DC Converters For the alternative renewable energy applications, there is growing concern about multiport dc-dc converter because of its attractive features such as lower switching devices, universal controller and flexible power flow control strategy. Fig. 2.9 gives a three-port converter topology [17 - 18]. The proposed converter is formed by a half-bridge topology with a free-wheeling branch. The two input ports are connected to the dc link and middle point of capacitors. The gate signals of three switches are turned on in sequence and the power flow on two ports can be 11 controlled independently. The converter can achieved soft-switching on all of the switches over wide input voltage. But since the input current is discontinuous, it is more suitable for low power applications. On the other hand, the power flow on transformer is unidirectional so that the energy sources on primary side cannot be charged by the HVS source. S2 C2 D1 Lf Vin S3 D2 C1 Vbi S1 Vo Cf 1:n:n Figure 2.9 Tri-mode half-bridge converter i2 LVS Sa1 iLs HVS C1 Ls C3 i3 Sr1 1 : N ir i1 Ldc VH V1 V2 Sa2 Sb C2 C4 Sr2 2 Figure 2.10 Three-port bidirectional dc-dc converter 12 Based on current-fed boost dual-half converter, a three-port topology is proposed in [19 20] to interface 14V and 42V battery for vehicle applications. In Fig. 2.10 shows that another port is connected to the LVS dc link. The power flow between the LVS and HVS is controlled by phase shift angle, and the power distribution of two ports on LVS is controlled by duty cycle. Every port is bidirectional, so that the battery can be charged and discharged using this converter. 2.4 The Proposed Three-phase DAB Bidirectional DC-DC Converter In this thesis, a three-phase DAB bidirectional dc-dc converter is proposed for high power applications [21]. The topology integrates a three-phase boost converter with a threephase galvanically isolated bidirectional dc-dc converter. Keeping dc bus voltage constant allows high efficient energy conversion over a wide input voltage and maintains ZVS conditions in the whole operation range. By using compact small inductance dc inductors the ZVS conditions can be improved in low power range and the switching losses of the lower switches are reduced. At the same time the input current ripple can be alleviated by three-phase interleaved structure. The three phase current-fed DAB converter can also be utilized in multiport application. A three port integrated bidirectional dc-dc converter is proposed for PV system with battery backup. The three-phase interleaved topology is suitable for higher power application, and all three ports are capable of bidirectional power flow so battery can be charged from PV and the grid as well. 13 CHAPTER THREE 3 THREE-PHASE TWO-PORT DUAL-ACTIVE-BRIDGE (DAB) DC-DC CONVERTER 3.1 Introduction With the requirements of lower greenhouse gases, sustainable development of economics, and threat of exhaust of conventional energy source, etc, the application of renewable energy sources becomes more and more popular in every field of our life. Generally, the energy of renewable source is converted to the electricity power, however the utilization of renewable source is constrained by its wide varied terminal voltage range and intermittent characteristics. The new energy source or energy storage elements, such as PV have intermittent nature and varied terminal voltage to realize the max power point tracking (MPPT). The phase-shift controlled dc-dc converters have been reported in many literatures [1 - 6] as a good candidate to interface with such sources. Most of researches in the literatures focus on the voltage source DAB converters [7-18]. In the voltage source DAB converters, the DC-link voltage cannot be regulated by phase shift control. Therefore, the converter will fail to satisfy the soft switching conditions when the ratio of input to output voltage is not close to the transformer turns ratio [7]. Furthermore, the mismatch between the primary side and secondary side DC-link voltages will result in large RMS and peak current in both transformer and switches even in no load condition [8], thus high efficiency is hard to achieve over wide input or output voltage ranges [18]. In order to improve performance in wide operating range, many optimized modulation methods are proposed for voltage source DAB converters to maintain soft switching conditions and reduce reactive power loss. In [19], phase shift plus duty cycle control is used to maintain ZVS conditions, but the maximum phase shift is constrained and the power flow is therefore limited. A novel dual-phase-shift control is proposed in [20] to eliminate reactive power and increase system efficiency when input and output voltages do not match. In this case, the converter control becomes complicated due to the output power being related to two phase shift variables, and the circulating current still exists in this mode even though the reactive power is eliminated totally. A hybrid modulation method is applied to extend power range for 14 ultracapacitor application in [21], in which a proposed triangular modulation and common phase shift modulation are applied together to increase the power transfer range with wide input voltage. Current-fed topology provides another solution to improve performance for the wide operating range. In [22], an isolated boost full-bridge DC-DC converter is addressed to fulfill the requirements of wide voltage range, bidirectional power flow and high-efficiency. Another current-fed dual-half-bridge (DHB) converter is proposed for fuel cell application [23], in which the DC-link voltage of low voltage side can be controlled by adjusting the duty cycle. In these two current-fed converters, auxiliary clamp circuit or comparable large DC inductors are required to avoid voltage spikes and high input current ripples. Although current-fed topologies have advantages to improve performance for the wide operating range compared to the voltage-fed counterparts, a large dc inductor is usually required to lower the input current ripple. In addition, the dc inductor current will affect and complicate the soft switching condition analysis. In this chapter, a three-phase current-fed dual-active-bridge (DAB) DC-DC converter with isolated Y-Y connected transformers is proposed to solve the above issues. The major features of the proposed converter are as following: (1) Increased converter power rating by paralleling phases; (2) Reduced size of input DC inductors and DClink capacitor with interleaving structure; (3) Maintained soft switching conditions and high efficiency over a wide load range and wide input voltage range without auxiliary circuitry; and (4) Easy-implemented power flow management because of decoupled duty cycle and phase shift control. In this chapter, the voltage-fed topology will be discussed firstly, and the operating modes are presented in detail. The current-fed topology is similar to the voltage-fed type, but it can handle with various input voltage. Since the duty cycle is a control variable to make the dclink voltage constant, the operating modes are more complex than those of voltage-fed type. 15 LVS ii Sa1 ia C1 O Ldc1 ib Ldc2 ic Ldc3 Sb1 a Sc1 Sr1 isa Ls1 b isb ir Ls2 c Ls3 n io HVS 1 : N m Ss1 St1 Vo O' C2 R L r s is t it isc Vin Sa2 Sb2 Sr2 Sc2 Ss2 St2 Figure 3.1 Proposed three-phase current-fed dual-active-bridge bidirectional DC-DC converter 3.2 The Proposed Topology and Comparison 3.2.1 Topology Description The topology of proposed converter is shown in Fig. 3.1, which consists of three DC inductors and a three-phase DAB bidirectional DC-DC converter. A low voltage energy storage element such as battery or ultracapacitor can be connected in the current-fed port and the high voltage side can be connected to the high voltage DC bus to provide power to inverter for specific applications. The converter can be operated in boost mode when the power flows from low voltage side (LVS) to high voltage side (HVS) or in buck mode when the energy source absorbs power from HVS. In the boost mode, the boost function is achieved by DC inductors and three half bridges on LVS, to keep DC bus voltage constant so as to allow high efficiency conversion for wide varied input voltage source. Comparatively, in buck mode, three small DC inductors Ldc1 – Ldc3 are used as filters to smooth the charging current. In order to achieve soft switching and reduce the turn-off switching loss, small snubber capacitors are paralleled with the MOSFETs on LVS and HVS. Three single-phase high frequency transformers are connected in Y-Y type to reduce circulating current and alleviate current unbalance issue. The leakage inductance is implemented in each transformer as an energy transfer element. Benefitting from interleaving structure, the three-phase current-fed DAB converter has much smaller passive components comparing with the single-phase DHB converter. Similar to 16 van ωt vrm φ idc_a 0 π/3 ia HVS LVS Dr1 on Dr2 Sr2 on on Da1 on t1 t2 t3 Sa1 Sr1 gated gated on on π 2π/3 5π/3 4π/3 Dr2 on Sr1 on t5 t6 Sa2 on Da2 t7 t8 on Sa2 Sc1 Sr2 St1 Sb1 Ss1 Sb2 Ss2 gated gated gated gated gated gated gated gated on on on on on on on on Dr1 on Sr2 on Da1 on Sa1 on Sa1 on t4 Sc2 St2 gated gated on on ωt 2π t9 Sa1 Sr1 gated gated on on Sc2 gated on (a) van ωt φ vrm idc_a 0 π/3 ia HVS LVS Dr2 on Sr2 on Da1 on t1 t2 π 2π/3 Dr1 on Sa1 on t3 t4 5π/3 Sr1 on t5 t6 Da2 on ωt 4π/3 2π Dr2 on Sr2 on Sa2 on t7 t8 Da1 on t9 Ss1 Sc1 Sr2 Sb2 St1 Sa1 Ss2 Sc2 Sr1 Sa1 Ss2 Sc2 Sr1 Sb1 St2 Sa2 gated gated gatedgatedgated gated gated gated gatedgated gated gated gated gated gatedgated on on on on on on on on on on on on on on on on (b) Figure 3.2 Voltage and current waveforms in transformer and DC input inductor: (a) φ ≤ π/3; (b) π/3 < φ < 2π/3; 17 the three-phase DAB converter, the gate signals for upper and bottom switches on each phase are complementary, with the phase angle 2π/3 between phase legs on one side. The power flow is bidirectional by controlling the phase shift angle between the active switches on LVS and HVS. Unlike the fixed duty cycle control in voltage source DAB converter, the duty cycle is controllable to keep the DC-link voltage constant on LVS in wide input voltage range or to keep the DC-link voltages on both sides to be matched. Due to the two control variables, duty cycle D and phase shift angle φ, the operation will be more complicated than voltage source three-phase DAB (DAB3) converter. Detailed analysis will be given in the following. 3.2.2 Operating Mode Analysis 3.2.2.1 50% Fixed duty cycle Considering that the duty cycle is 50% fixed, the operation principle is similar to the three-phase voltage source DAB converter. The power equation can be derived by the integration of the instantaneous power p(t) over one switching period, Po 3 2 2 0 v an ( t )ia (t )dt (3.1) Where the van(ωt) is the voltage on the primary side of transformer and ia(ωt) is the primary side transformer current. Fig. 3.2 shows the voltage and current waveforms on transformer in different cases. Taking phase a in case a as an example, ignore the capacitor resonance during the dead time zone which is discussed in [23], and the interval t1 to t9 of Fig. 2 (a) can illustrate the stages of operation during one switching period. The situation of switches on LVS is determined by the sum of dc inductor current idc_a and transformer current ia, and stage of switches on HVS is just depended on the transformer current. The brief description of each stage is given as follows. Stage 1 t1-t2: At t1, Sa1 is gated on. ia is increasing but negative, so Dr2 is conducting. idc_a is decreasing but higher than ia, thus Da1 is conducting in accordance of Kirchoff’s Current Law (KCL). Stage 2 t2-t3: At t2, ia increases to be positive and Sr2 begins to conduct. But it is lower than idc_a, so Da1 continues conducting. Stage 3 t3-t4: At t3, Sr1 is gated on. ia is positive and Dr1 is conducting. idc_a continues decreasing but ia is still lower than idc_a, therefore Da1 is conducting. 18 Stage 4 t4-t5: At t4, idc_a decreases and is lower than ia, so Sa1 begins to conduct. Stage 5 t5-t6: At t5, Sa2 is gated on. Since ia is higher than idc_a, Dr2 conducts first until t6 when idc_a surpasses ia. Stage 6 t6-t7: At t6, Sa2 begins to conduct. ia is positive, so Dr1 continues conducting. Stage 7 t7-t8: At t7, ia decreases to be negative and Sr1 begins to conduct. Stage 8 t8-t9: At t8, Sr2 is gated on. ia is negative, so Dr2 is conducting. At t9, one switching period is completed and the converter operation will repeat. The stage of operation of case b can also be derived in the same way. The exact value of van(ωt) can be expressed as, V d 3 ,0 t / 3 2V v an ( t ) d , / 3 t 2 / 3 3 V d ,2 / 3 t 3 (3.2) There is a phase delay φ between van and vrm, v rm (t ) v an (t ) (3.3) The voltage on the leakage inductance is the difference between van and vrm. For each time interval, van and vrm are constants, so the current on leakage inductance can be calculated as, ia (t ) ia (t 0 ) Van Vrm (t t 0 ) Ls (3.4) Where ia(ωt0) is the initial current of corresponding time interval. ia(ωt) can be expressed by ia(0) using iterative method. As D was given 1/2, the current waveform is symmetrical in one switching period, i.e. ia(0) = - ia(π). Solve for ia(0), 2Vd (1 d ) / 2 d , 0 /3 3L s i a (0) 2Vd 3d ( / 2) , / 3 2 / 3 9L s (3.5) Where d = Vo/N·Vd, and N is the transformer turns ratio. According to (3.3) – (3.5), the current in each time interval can be obtained and the power equation can be calculated as, 19 Po _ DAB 3 dVd2 (4 3 ) , /3 6 Ls 2 2 dVd (18 18 / ) , / 3 2 / 3 18 Ls (3.6) In order to minimize the peak current and RMS current, the voltages on LVS and HVS should be matched, i.e. d = 1. The base power is defined as, 1p.u. = Vd2/ωLs, and the power equation could be rewritten as, (4 3 ) , / 3 6 Po _ DAB 3 ( p.u.) 2 2 18 18 , / 3 2 / 3 18 (3.7) If the neutral points of transformer n and m are connected to the corresponding middle points (o and o΄) of DC-link capacitors, the converter turns to be three interleaving single-phase DHB (3DHB) converter [24] and the power equation will be, Po _ 3 DHB ( p.u.) 3 ( ) ,0 4 (3.8) Fig. 3.3 shows the power curves of DAB3 and 3DHB converters. Under the same conditions, 3DHB converter has higher output power than DAB3 before 60° phase shift angle. The maximum output power of two converters are both at π/2, Po _ max 7 36 0.611 p.u. , DAB 3 3 0.589 p.u. ,3DHB 16 (3.9) On the other hand, the transformer size and reactive power loss are determined by apparent power rating, which can be calculated by: S 3Van _ rms I a _ rms , (3.10) Where the RMS value of current for different converter is, I a _ rms V 2 d 3 Ls V 2(4 3 ) d 6 Ls Vd (3 2 ) Ls 6 ,0 / 3 DAB3 , / 3 2 / 3 (3.11) 3DHB 20 Define the ratio of Po/S as power factor (PF) of the transformer, and PF on these 2 converters can be derived as: (4 3 ) , 0 3 2 2 (2 ) 3(18 2 18 2 ) 2 , PF 2 2 3 3 3 3 2 6 (9 81 54 ) 3( ) 3 (3 2 ) 1 (3.12) ,3DHB 0.66 0.9 0.6 0.8 0.48 0.7 0.36 0.6 0.24 0.5 0.4 0 0.12 DAB3 3DHB 20 40 60 φ/º P/p.u. Po PF Power Factor , DAB3 80 100 0 120 Figure 3.3 Comparison of Power and power factor for DAB3 and 3DHB converters 21 1 DAB3 3DHB 0.9 0.9 Power Factor 0.8 0.8 0.7 0.7 0.6 0.6 0.5 0.5 0.4 0.4 0 0.1 0.1 0.2 0.2 0.3 0.4 0.3 0.4 P/p.u. 0.5 0.5 0.6 0.6 Figure 3.4 Comparison of power and power factor for DAB3 and 3DHB converters The power factor curves are also plotted in Fig. 3.3. As shown, the PF of 3DHB decreases faster than DAB3 with the phase shift angle increasing. Furthermore, the curves of PF versus output power are also plotted in Fig. 3.4. It shows that the power factor of DAB3 converter is always higher when generating the same real power, therefore less reactive power loss and higher efficiency is expected in DAB3 converter. 22 3.2.2.2 Varied duty cycle Another feature of current-fed DAB3 converter comes from its ability to interface with voltage varied energy source. With the changes of the input voltage, duty cycle D is controlled to keep the DC-link voltage constant. For different duty cycle D and phase shift angle φ, the operating range can be divided into six areas, which are shown in Fig. 3.5. The corresponding current waveforms in different operating areas are also given in Fig. 3.5, and according to different current waveforms and voltage, the corresponding power equations can be derived. The calculation process of power flow is similar to the fixed duty cycle, which is described in (3.13): Po _ DAB 3 I K (4 D ) / 2 , 2 2 K 4 (3D 1) sgn( ) 3 (9 4 12 D ) / 36 , II III K (4 3 ) / 6 , 1 2 2 IV K 18( D 2 ) sgn( ) 18 ( ) / 9 , K 4 2 (2 3D) 2 sgn( ) 3 (9 16 12 D ) / 36 , V K (4(1 D) ) / 2 , VI (3.13) Where K = Vd2/ωLs. The 3D power flow is plotted in Fig. 3.6, and the global maximum power is still located at (1/2, π/2). In the practical use, duty cycle D is limited in [1/3, 2/3] considering the efficiency of converter and the variation range of input voltage, so that the DC-link voltage of LVS can keep constant with 100% variation of input voltage, i.e. Vin ∈ [Vd/3, 2Vd/3], which includes area II, III, IV and V. Therefore we focus on this operating range in this study. The power of current-fed 3DHB converter can be derived similarly, 3 (4 D 4 D 2 ) Po _ 3 DHB ( p.u.) , 2 / 3,1 / 3 D 2 / 3 4 23 (3.14) φ 2π/3 isa φ isa IV Area I 2π I φ V II VI III isa φ Area II 1/3 2π 1/2 D Area IV 2π φ isa 2/3 Area V 2π φ isa isa -2π/3 φ Area III Area VI 2π 2π Figure 3.5 Six operating areas with different (D, φ) and corresponding transformer current waveforms 0.6 0.6 0.4 0.4 DAB3 Po/p.u. 0.2 0.2 00 -0.2 -0.2 -0.4 -0.4 -0.6 -0.6 120 90 120 φ/º 60 60 30 30 0 00 0.2 0.2 0.6 0.6 0.4 0.4 0.8 0.8 D Figure 3.6 Power flow versus duty cycle D and phase shift angle φ 24 11 0.6 0.2 Po/p.u. 0.15 0.45 0.1 0.3 0.05 0.15 DAB3 3DHB 00 120 120 90 90 φ/º 60 60 30 30 0 0 0.35 0.35 0.4 0.4 0.45 0.45 0.5 0.5 0.55 0.55 0.6 0.6 0.65 0.65 D Figure 3.7 Power flow of DAB3 and 3DHB converter with different (D, φ) In Fig. 3.7, the power flow curves of DAB3 and 3DHB in 3D plot were drawn. The grey and black areas are the power of 3DHB and DAB3 converter, respectively. As shown, the power of 3DHB is higher than that of DAB3 converter with φ < 60˚, which has the same conclusion as the case of 50% fixed duty cycle. The reactive power on transformer and PF values of two converters can be calculated piecewise. Fig. 3.8 shows the PF curves versus phase shift angle φ in different D. The PF achieves the highest value at D = 1/2 which will decrease when D is moving away from 1/2. Furthermore, the PF in DAB3 is always higher than 3DHB until D comes to 1/3 or 2/3, where they are squared. 25 1 0.8 DAB3 3DHB D=0.5 D=0.4,0.6 D=1/3,2/3 0.7 D=0.4,0 .6 0.9 Power Factor D=0.5 0.6 D=1/ 3,2/3 0.5 0.4 0.3 0.3 0 20 40 40 60 60 φ/º 80 80 100 120 120 Figure 3.8 PF of DAB3 and 3DHB converter with different (D, φ) Fig. 3.9 also gives a comparison of PF between DAB3 and 3DHB -- the ratio of PFDAB3 to PF3DHB is always higher than 1. The analysis above indicates clearly that the reactive power loss increases with the increasing of phase shift angle, and the reactive power loss in D = 1/2 is the smallest value so that the power efficiency is the highest. Practically, the magnetic flux swing and RMS current rating in transformer should be considered separately. For example, the power density can be higher at D = 1/3 [25], as the maximum flux swing is smaller than D =1/2, which means smaller core or winding turns are needed. Thus, in application level, different D is chosen in voltage type converter based on different criteria. 26 1.12 1.12 1.1 1.1 PFDAB3/PF3DHB PFDAB3/PF3DHB 1.08 1.08 1.06 1.06 1.04 1.04 1.02 1.02 11 120 120 90 90 60 60 φ/º 30 30 00 0.35 0.35 0.4 0.4 0.45 0.45 0.5 0.5 0.55 0.55 0.6 0.6 0.65 0.65 D Figure 3.9 Comparison of PF of DAB3 and 3DHB converter with different (D, φ) When the input voltage changes, current-fed DAB3 (CF-DAB3) converter has smaller RMS current on the MOSFETs compared with the voltage type DAB3 converter. Define the base input voltage Vin_DAB3(1p.u.) = Vo/N, Vin_CF-DAB3(1p.u.) = Vo/2N, and RMS current on MOSFETs can be calculated and plotted in Fig. 3.10. As shown, when Vin = 1p.u., voltage source DAB3 converter has smaller RMS current value compared with CF-DAB3. But when Vin changes, the RMS current on current-fed type will be lower than voltage type since it is able to maintain “d=1” by controlling the duty cycle D. In summary, CF-DAB3 converter is a suitable topology for renewable energy source applications. 27 CF-DAB3 DAB3 0.5 Vin=2/3p.u. Irms2/p.u. 0.4 0.3 Vin=1p.u. 0.2 0.1 0 Vin=4/3p.u. 0 10 20 30 40 50 60 φ/º Figure 3.10 RMS current curves on LVS MOSFETs 3.3 Analysis of ZVS Conditions In section 3.2, we showed that the reactive power in DAB3 is lower than in 3DHB converter, which also indicates the difficulty in maintaining soft switching conditions compared to DHB converter, as DAB3 converter has less reactive current. However, the ZVS condition is more critical in the current-fed type due to the effect of DC inductor current. This section will focus on the analysis of the ZVS conditions for DAB3 under different duty cycle and also find the relationship between the soft switching conditions and DC inductor. 3.3.1 ZVS Conditions for Voltage Source DAB3 Converter In [8], the ZVS conditions are detailed analyzed at D =1/2. However, the ZVS conditions will also vary when D changes. The ZVS conditions of voltage type DAB3 converter turn to be, 28 iLs (0) 0, i (2 D ) 0, Ls iLs ( ) 0, iLs (2 D ) 0, for LVS upper switches for LVS lowerer switches for HVS upper switches (3.15) for HVS lower switches According to the calculation in Section 3.2, the current values can be obtained, as well as ZVS conditions in different operating area. The ZVS conditions of each switch in operation area III can be further simplified to, d d d d 2 , 2 3 2 3 , 2 2 , 2 3 2 3 , 2 for LVS upper switches for HVS upper switches , Area III (3.16) for LVS lower switches for HVS lower switches Similarly, ZVS conditions in other operation areas can also be described by d and φ. Fig. 3.11 plots the ZVS boundaries when D varies from 1/3 to 2/3. As shown, the ZVS boundaries will vary with various duty cycles, but ZVS is very well maintained on all switches when the DC-link voltages on LVS and HVS match each other. Therefore, d = 1 is the key point to keep ZVS conditions and lower switching loss. 3.3.2 ZVS Conditions for Current-fed DAB3 Converter For the current-fed topology, the ZVS conditions are complicated than voltage source type, since the DC input current changes the current waveforms on the switches of LVS. However, the transformer current is not affected by DC input current, thus the ZVS conditions on HVS switches are the same as voltage source DAB3 converter. ZVS conditions in boost mode and buck mode are symmetrical [23], so only boost mode is considered in this study. Fig. 3.12 shows the circuits of one leg on LVS and HVS, as well as the denotation of current in each branch. Write the ZVS conditions on LVS as, ils (0) idc (0) 0, idc (2 D ) ils (2 D ) 0, for LVS upper switches for LVS lower switches 29 (3.17) D=1/3(2/3) 0.25 0.2 P/p.u. Spu(Spl) ZVS boundary Hard-switching Soft-switching pl: primary lower switch pu: primary upper switch sl: secondary lower switch su: secondary upper switch Spl(Spu) d=1.5 d=1 0.15 d=0.75 Ssl(Ssu) 0.1 0.05 0 Ssu(Ssl) 0 0.2 0.4 φ/rad 0.6 0.8 1 (a) D=1/2 Spl Spu 0.25 d=1.5 Po/p.u. 0.2 d=1 0.15 d=0.75 0.1 Ssu Ssl 0.05 0 0 0.2 0.4 φ/rad 0.6 0.8 1 (b) Figure 3.11 ZVS boundaries and power curves at different D: (a) D = 1/3, 2/3; (b) D = 1/2 30 LVS HVS Spu idc Ldc C1 Vd Sr1 ipu is Ls ir r a isl ipl Vin isu O' C2 RL Vo Sr2 Spl Figure 3.12 The middle points of one leg on LVS and HVS 2Dπ 2π idc ΔI Idc_avg ωt 0 φ Figure 3.13 DC inductor current in one switching period The DC input current is related to the input power and DC inductor, which is shown in Fig. 3.13. Three operating areas (D [1/3,2/3],φ [0,π/3]) are under consideration here. By calculation, if d = 1, the ZVS conditions are always satisfied when d = 1, except in area III. The ZVS conditions in Area III are described in (3.18), 31 P 1 Vd (1 D)Vin 0, 2 2d 3d o _ III Ldc 3Vin 9 Ls Po _ III 1 Vd 2 2d 3d (1 D)Vin 0, Ldc 3Vin 9 Ls for LVS upper switches , Area III (3.18) for LVS lower switches In (3.18), the upper switches on LVS can be soft switched, but the ZVS condition on lower switches is related to the DC inductor. Define m = Ldc/Ls, and the in-equation in (3.18) can be simplified to: (4 3 ) D(1 D) 0 18 D m 3 (3.19) Fig. 3.14 plots the ZVS region under different m, and it is clear that the soft switching region will increase when m decreases. Small DC inductor will result in large input current ripple, but the current ripples on each phase can be cancelled each other using interleaving strategy so the total current ripple can be alleviated significantly [26]. 2 Hard switching region 1.5 Soft switching region Soft switching region m=Ldc/Ls 1 ZVS boundaries φ/rad 0.5 15 50 0 m=∞ 100 100 15 50 -0.5 -1 -1.5 Soft switching region -2 0 0.1 0.2 0.3 0.4 0.5 D 0.6 0.7 Figure 3.14 ZVS boundaries under different m 32 0.8 0.9 1 3.4 Analysis of Unbalance Issue Comparing to the single phase converters, multiphase converters have many advantages, but phase current unbalance is an important issue that should be solved. It is necessary to find the reason of unbalance current and solution to alleviate the impact. 3.4.1 Analysis of Current Unbalance According to the power equation, since the phase current is inversely proportional to the leakage inductance, the unbalanced leakage inductance will lead to unbalanced phase current. In [27], the relationship between phase current unbalance ratio (ΔIφ%) and leakage inductance unbalance ratio (ΔLs%) was analyzed. Different transformer connection type has different impact on phase current. There are several sub types in DAB3 converter according to different transformer connection. Y-Y connection and Δ-Δ connection model can be transferred each other, which are shown in Fig. 3.15, so they have the same operation modes. Due to the features of phase shift method, the voltage waveforms on both sides of the transformer should have the same shape to avoid high reactive current, thus Δ-Y (or Y-Δ) connection type is not recommended. Fig. 3.16 shows the different transformer connection type of DAB3 and 3DHB converters. In Fig. 3.16, two different Δ-Δ types are distinguished by the position of leakage inductance. For Δ-Δ type DAB3 converter, the unbalanced leakage inductance will result in unbalanced transformer current, as well as unbalanced phase current. a a ia ia iab Ls L sca ab Lsa Lsb Lsc ica ib b ib ic b c ibc Lsbc Figure 3.15 Transformation between Y-model to Δ-model 33 ic c Take Fig. 3.16 (c) as an example, and define Kxy(xy=ab,bc,ca) as the coefficient to describe how far away the leakage inductance of each transformer is from the normal value Lφ0, then, Lxy K xy L 0 (1 K xy ) L 0 , xy ab, bc or ca (3.20) Where ΔKab+ ΔKbc+ ΔKca=0. The fundamental model [8, 28] is applied in this study, and the current and voltage phasors are shown in Fig. 3.17. The phase voltage on HVS lags corresponding phase voltage on LVS φ0. The transformer current iab is calculated as, V0 Vab Vab (1 K ab ) I ab 2 jLab jL 0 K ab L 0 (3.21) Where |ΔV0|=Vdφ0sin(Dπ)/π. So the amplitude of iab is, V0 (1 K ab ) (1 K ab ) I 0 I ab L 0 (3.22) The phase current ia can be obtained by, I a I ab I ca V0 Vab Vca jL 0 K ab jL 0 K ca L 0 2 2 K ab K ca K ab K ca (Vab ) K ab K ca 3 (3.23) By simplifying (3.23), we can get, Ia I0 K bc 1 )I 0 (1 1 (K ab K ca ) / 2 2 34 (3.24) Lsa a a r Lsa r Lsb b m s n t Lsc c t L L sb sc s c b (a) (b) c Lsc c t L sb t Ls ca c a r s s r b Lsab a (c) Lsa Lsb b (d) Figure 3.16 Four Transformer connection types DC-DC converter (a) Y-Y DAB3; (b) 3DHB; (c) Δ-Δ DAB3 with integrated Ls; (d) Δ-Δ DAB3 with external Ls; 35 Vbc V fst I bc V fbc b a V fab I ab c Vab V frs V ftr I ca Vca V fca Figure 3.17 Phasor diagram of phase voltage and current From (3.22) and (3.24), it can be seen that the transformer current unbalance ratio is the same as that of leakage inductance, i.e. Δiab ~ -ΔKab, and the phase current unbalance ratio is just half of it, i.e. Δia ~ ΔKbc/2. Using the same method, the relationship of current unbalance ratio and leakage inductance for other types of converters can be found and listed in Table 3.1. In table 3.1, “A” and “D” have the same performance that ΔI/I0 is halved comparing with ΔI/I0, so they have inherent current sharing capability. The ΔI/I0 in topology “B” is equal to ΔK of its own phase. In “C” the ΔI/I0 of phase current and that of transformer current are not consistence, which also implies that phase current and transformer current cannot be controlled to balance at the same time. In part B, the current sharing control analysis will be given in detail. 36 Table 3.1 ΔI/Iavg resulting from unbalanced leakage inductance Index Connection type A Y-Y connection Phase current Transformer current ΔIa/I0 = -ΔKa/2 ΔIb/I0= -ΔKb/2 ΔIc/I0= -ΔKc/2 B ΔIa/I0 = -ΔKa 3DHB ΔIb/I0= -ΔKb ΔIc/I0= -ΔKc C D Δ-Δ connection with ΔIa/I0= ΔKbc/2 ΔIab/Iφ0= -ΔKab integrated Ls ΔIb/I0= ΔKca/2 ΔIbc/Iφ0= -ΔKbc ΔIc/I0= ΔKab/2 ΔIca/Iφ0= -ΔKca Δ-Δ connection with ΔIa/I0= -ΔKb/2 ΔIab/Iφ0= -ΔKc/2 external Ls ΔIb/I0= -ΔKc/2 ΔIbc/Iφ0= -ΔKa/2 ΔIc/I0= -ΔKa/2 ΔIca/Iφ0= -ΔKb/2 *: the subscript of K depends on the position of the Ls 3.4.2 Current Sharing Control Though topology “A” and “D” have inherent current sharing capability, the phase current are still asymmetrical when leakage inductances are not equivalent. The current sharing controller should be developed to make the current balance. We still use topology “C” as the objective, but transfer Δ-model to Y-model for simplicity. Define phase shift angles on each phase, a a 0 b b 0 c 0 c (3.25) Where σx(x=a,b or c)=1+Δσx is the coefficient to describe how far away the phase shift angle of each phase is from the normal value φ0 and Δσa+ Δσb+ Δσc=0. The phase current ia can be expressed as, 37 V0 (1 a ) Van (1 a ) Ia (Van ) I 0 (Van ) jLsa L0 (1 K a ) 2 (1 K a ) 2 (3.26) In order to let |Ia| equal to the average value |I0|, 1 a 1 1 K a (3.27) x K x , x a, b or c (3.28) So we have, Consider the transformer current Iab in Δ-model. c (1 ) V 0 (1 ab ) Vab 2 (Vab ) I 0 (Vab ) I ab jLsab 3L0 (1 K c ) (1 K c ) 2 2 (3.29) To make the transformer current iab balance, the regulation of phase shift angle is, c ) 2 1 (1 K c ) (1 (3.30) So for three-phase system, the regulation of phase shift angle is, x 2K x , x a, b or c (3.31) The equations (3.28) and (3.31) cannot be satisfied at the same time, so for topology “C” there is no current sharing controller which can make the phase current and transformer current to be balanced. Using the same method, the regulation of phase shift angle in other topology can be calculated and listed in Table 3.2. In Table 3.2, only topology “C” cannot realized current sharing control, so Δ-Δ type should be avoided if using integrated leakage inductance as the main power transfer element. Based on the relationship between phase shift angle and unbalanced current ratio, the ratio of each phase shift angle σx can be set and applied to phase shift controller. Fig. 3.18 shows the flow chart of ratio presetting current sharing control, where Ni is the times of tuning (1 ~ ∞). Using this method, the ratio of phase shift angle can be tuned faster than a PI controller. 38 Table 3.2 The relationship between regulation of φ and ΔI/Iavg Index Connection type A Y-Y connection ΔIa/I0 = Δσa/2; ΔIb/I0= Δσb/2; ΔIc/I0= Δσc/2 B 3DHB ΔIa/I0 = Δσa; ΔIb/I0= Δσb; ΔIc/I0= Δσc C Δ-Δ connection with integrated Ls D Phase current Transformer current ΔIa/I0= Δσa/2 ΔIab/Iφ0= Δσc ΔIb/I0= Δσb/2 ΔIbc/Iφ0= Δσa ΔIc/I0= Δσc/2 ΔIca/Iφ0= Δσb Δ-Δ connection with ΔIa/I0= Δσa/2 ΔIab/Iφ0= Δσc/2 external Ls ΔIb/I0= Δσb/2 ΔIbc/Iφ0= Δσa/2 ΔIc/I0= Δσc/2 ΔIca/Iφ0= Δσb/2 The simulation in Psim is to verify the analysis. In the simulation, the leakage inductances were selected as: Lsa = 520nH, Lsb =444nH, Lsc =370nH, which demonstrated 17% inductance unbalance. Fig. 3.19 and Fig. 3.20 show the simulation results for split capacitor and Y-Y type converters when output power is 4kW and input voltage is 24V. For split capacitor type converter, without current sharing control, the phase shift angle is 0.043π and the phase current are Isa = 34.9A, Isb = 40.9A and Isc = 49.1A, respectively, which are shown in Fig. 3.19 (a) and have 16% unbalance ratio. With current sharing control, the phase shift angles are different and the phase current are balanced with the value 41.6A. With current sharing control, square of RMS current value decreases from 5302 A2 to 5217 A2, so it will help to decrease the conducting loss and improve the efficiency. For Y-Y type converter, without current sharing control, as shown in Fig. 3.20(a), the phase shift angle is 0.043π and Isa = 37.7A, Isb = 41.2A and Isc = 44.2A, which have only 8.7% difference. With current sharing control, the phase current is balanced and Isa = Isb = Isc = 41.0A. The square of RMS current value decreases from 5115 A2 to 5018 A2. Comparing Y-Y type with split capacitor type, former has smaller RMS current and higher efficiency. 39 Start Calculate Iaverage Calculate ΔIa%, ΔIb%, ΔIc% Ir Is It Update Ir, Is, It σa=σa(1-2ΔIa%), σb=σb(1-2ΔIb%), σc=σc(1-2ΔIc%), Save σa, σb, σc φa=σaφ0, φb=σbφ0, φc=σcφ0, N n=Ni? Y End Figure 3.18 Flow chart of ratio presetting current sharing control 40 ir / A /103 80 60 40 20 0 -20 -40 -60 I sc=49.1A I sb=40.9A Isa =34.9A 43.75 43.70 43.65 43.60 43.55 43.50 43.45 φ=0.0436π 0 12 6 18 24 30 t/µs (a) ir / A 80 60 40 20 0 -20 -40 Isc=44.2A Isb=41.24A Isa=37.68A /103 43.56 43.55 φ=0.0436π 43.54 0 5 10 15 20 25 30 t/µs (b) 40 ir / A 20 Isc=27.8A Isa=19.8A Isb=23.2A Ic=44.6A Ia=39.8A Ib=38.2A 0 -20 -40 ir / A 80 60 40 20 0 -20 -40 t/µs (c) Figure 3.19 Phase current and transformer current waveforms without unbalance controller: (a) Split-cap type; (b) Y-Y type; (c) Δ- Δ type 41 ir / A /103 80 60 40 20 0 -20 -40 55 50 Isb=41.6A φa=0.052π 45 φb=0.045π 40 35 Isa=41.6A Isc=41.6A 0 5 φc=0.037π 10 15 20 25 t/µs /103 ir / A (a) 80 60 40 20 0 -20 -40 55 50 φa=0.0514π 45 φc=0.0369π φb=0.0444π 40 35 Isa=41.0A Isc=40.9A Isb=41.0A 0 5 10 15 20 25 30 t/µs (b) il / A ir / A 40 20 Isc=25.6A 0 Isb=23.7A Isa=21.7A -20 -40 80 60 40 20 0 -20 -40 0 Ic=40.9A 5 Ib=40.9A Ia=40.9A 10 15 20 25 30 t/µs (c) Figure 3.20 Phase current and transformer current waveforms with unbalance controller: (a) Split-cap type; (b) Y-Y type; (c) Δ- Δ type 42 3.5 Converter Design Guideline 3.5.1 Transformer Design A 6kW converter is designed with varied low input voltage (24V - 48V) and rated high output voltage 288V. The DC-link voltage on LVS Vd = Vin/D is keeping constant, therefore the transformer turns ratio is determined by N = Vo/Vd = DVo/Vin = 4. The leakage inductance is integrated into the transformer. Comparing to traditional transformers, PCB planar transformers provide better consistency and flexibility. Each transformer consists of 2 E64-3C92 planar cores with separate primary and secondary PCBs. The primary and secondary windings have 4 turns and 16 turns respectively. Each turn on LVS and HVS is made up of two paralleled 4 oz copper windings, therefore satisfying the requirement of current density and helping to reduce AC resistance. Though the interleaving transformer windings structure can reduce the AC resistance significantly, it is very hard to provide enough leakage inductance as energy transfer element thus additional leakage inductance is needed. By using two separate PCB windings as primary and secondary winding, the desired leakage inductance can be controlled by adjusting the distance between the two PCBs. The single-phase transformer prototype is shown in Fig. 3.21. The primary and secondary PCBs are separated by a thickness hΔ and the leakage inductance for the non-interleaved structure is given in (3.32) [29]: Ls 0 N 2 lw h1 h2 h bw 3 (3.32) Where μ0 is the permeability of air (H/m), N is turns ratio, lw is the mean length of traces (m), and bw is the width of primary trace (m). h1 and h2 are the thickness of primary and secondary side, and hΔ is the distance between them. Table 3.3 gives the designed and measured leakage inductance of each transformer. 43 Insulation Layer h2 Secondary Side PCB hΔ h1 Primary Side PCB Primary Side Copper Layer Secondary Side Copper Layer Insulation Layer Figure 3.21 The sectional view of transformer Table 3.3 Leakage inductance of each phase (refer to LVS) Leakage inductance Designed Ls 510nH Measured Lsa 511.8nH Measured Lsb 517.5nH Measured Lsc 505nH 44 3.5.2 DC Inductor Design The main goals of DC inductor design are to maintain the ZVS and achieve small size. The DC inductance should meet the in-equation (3.21), i.e. Ldc < 11Ls. In the experiment, the DC inductor is designed as Ldc = 12Ls = 6μH, so the phase current ripple Idc is as large as 2Idc at rated power, and at the same time ZVS can be guaranteed in a majority of operation area. For three-phase interleaving structure, the total input current ripple is given as, I tot _ ripple 3Vd ( D 1/ 3)( D 2 / 3) f s Ldc (3.33) 20 18 16 Itot_ripple/A 14 12 10 8 6 4 2 0 0.35 0.4 0.45 0.5 0.55 0.6 D Figure 3.22 Input current ripple versus duty cycle 45 0.65 Fig. 3.22 shows the total input current ripple will reach zero at D = 1/3 and 2/3 but maximum value is 20A at D = 1/2. 3.5.3 Power Loss Analysis The power loss of converter is the key factor for components selection and design. For DC-DC converters, the losses are mainly caused by switching loss and conduction loss. For the switching loss, the converter is operating in ZVS situation, so there is no turn-on loss, only turnoff loss is considered, which can be approximately calculated by [30], Psw _ off 2 2 I off t f fs (3.34) 24C Where Ioff is the turn off current, tf is the falling time of MOSFET, and C is the snubber capacitance. Larger snubber capacitance will get smaller turn-off loss, but it will cause turn-on loss especially at light load since there is not enough current to release the energy stored in the snubber capacitors and the ZVS condition will be unsatisfied. So choosing proper snubber capacitor is important. In the experiment, 0.2µF and 0.03 µF capacitors are selected as snubber capacitors on LVS and HVS MOSFETs, respectively. The conduction losses include the losses in DC inductor windings, MOSFETs and transformer windings. The current ripple IΔ on DC inductor is not related to the output power, which can be written as, I Vd D(1 D) Ldc f s (3.35) And the AC flux density of inductor can be calculated by, BAC Ldc I Ac N L (3.36) Where Ac is the sectional area of magnetic core, and NL is the turns number. BAC always exists even at no load thus AC core loss dominating the major power loss at the light load. When there is power drawn from the energy source, the RMS current value on each inductor is derived by, I Ldc _ rms 1 2 2 0 2 Po 1 I dx i ( )d I x 0 3Vin 2 2 Ldc 1 1 46 (3.37) Where Po is the output power and η is the efficiency. In order to find the transformer conduction loss, the transformer RMS current value can also be calculated as, I Ls _ rms Vd 1 2 2 3 Ls ( ) i t d t Ls 2 0 Vd 6 L s 2 , 2(4 3 ) D 1/ 2 (3.38) , D 1/ 3, 2 / 3 From equations (3.36) to (3.38), the DC inductor core loss can be obtained by the following empirical formula, PLdc _ core VeCm f x B y AC (3.39) where Ve is effective core volume of transformer, Cm, x, and y are coefficient related to core material. The DC inductor conduction loss is, PLdc _ con I 2 Ldc _ rms RLdc (3.40) The transformer core loss has the same form as equation (3.39), and the conduction loss can be written by PTx _ con I 2 Ls _ rms Rdc Rac (3.41) The total conduction loss of MOSFETs on HVS can be calculated as, PHVS _ con 6( I 2 Ls _ rms Rds _ on / 2) 3I 2 Ls _ rms Rds _ on (3.42) Where Rds_on is the turn on resistance of MOSFET. The conduction loss on one MOSFET of LVS is different from that of HVS since the dc inductor current will affect the current waveform in MOSFET. What’s more, the current flowing through the upper switches and lower switches are asymmetrical, the RMS values of current in different D can be calculated as follow, 47 I upper _ rms Vd 972 2 2 16524 3 19683 4 4 4 , D 1/ 3 L 324 s Vd 2(320 2 2 864 3 576 4 3 4 ) , D 1/ 2 144 Ls Vd 2(1944 2 2 34020 3 19683 4 16 4 ) , D 2 / 3 648 Ls I lower _ rms (3.43) Vd 17253 2 2 35235 3 19683 4 648 3 14 4 , D 1/ 3 162 L s Vd 6(1472 2 2 1760 3 576 4 4 ) , D 1/ 2 144 L s Vd 144828 2 2 246888 3 98415 4 2592 3 98415 4 , D 2 / 3 648 Ls (3.44) So the conduction loss of MOSFET on LVS can be expressed as, PLVS _ con 3( I 2upper _ rms I 2lower _ rms ) Rds _ on (3.45) For the transformer design, using 2 paralleled 4oz PCB windings to replace 8oz PCB winding, the AC resistance of transformer winding Rac is reduced from 2.9Rdc to 0.79 Rdc [31]. Define the ratio of total copper loss to DC copper loss FR= Ptot_loss/Pdc_loss, and the ratio of the conductor thickness h to the skin depth δ, i.e. ξ=h/δ. Fig. 3.23 shows FR versus ξ in different number of layers. It is clear that the total copper loss is reduced from 3.914Pdc_loss to 1.789Pdc_loss. In Fig. 3.23, when the number of copper layers M increases to 12, the total copper loss just decreases by 0.43Pdc_loss, but more counts of copper layers will increase the cost. 48 M=12 2 10 FR M=8 M=4 Ptot _ loss 101 Pdc _ loss X: 0.875 Y: 3.914 X: 0.295 Y: 1.362 0 10 -1 10 X: 0.44 Y: 1.789 0 10 1 10 h Figure 3.23 Total winding copper loss ratio versus ξ and number of layers M Fig. 3.24 gives the power loss distribution in different power rating at different duty cycle. It can be seen that the DC inductors’ loss always exists because of the ripple current and it is dominant at the light load, and the conduction loss and switching loss will be dominant at the heavy load. Fig. 3.25 shows the total power loss curve in different duty cycle. Lower power loss in D = 1/2 can be obtained due to the smaller transformer and switches’ current, which is also consistent with the analysis in section II. 49 600 600 Tx Cor D=1/3 Switch D=1/2 Conduction Lo D=2/3 Ldc Loss Capacitor Loss Capac Tx Core Loss Tx Core Loss Switching Loss Switching Loss Conduction Loss Conduction Loss Ldc Loss Ldc Loss Capacitor Loss 500 500 Ploss/W 400 400 300 300 200 200 100 100 00 0 1000 2000 Po/W 4000 6000 Figure 3.24 Ploss distribution in different output power in different D 600 500 D=1/3 D=1/2 Ploss/W 400 D=2/3 300 200 100 0 0 1000 2000 3000 4000 5000 Po/W Figure 3.25 Total Ploss curves in different D 50 6000 3.6 Control Strategies for Current-fed Topology 3.6.1 Small Signal Modeling In order to investigate the steady and dynamic performance of the converter, the average model of the converter is developed to analyze its steady state and dynamic performance. Because of the symmetric property of three-phase dc-dc converter, the multiphase converter can be treated as a single phase converter and the operation principles of boost mode and buck mode are similar. The state variables are the dc inductor current iLdc, the primary side dc-link voltage vd, and the output voltage vo. The state equation is given as, di Ldc Ldc dt vin Dvd dvd DiLdc io1 Cd dt vo dvo Co dt R io1 L (3.46) Since the power of each phase is: Vd2 (4 3 ) Po , when d 1. 18Ls (3.47) the average value of io1 referred to the primary side is, io1 Po Vd (4 3 ) Vd 18 Ls (3.48) The equivalent circuit of average model is presented in Fig. 3.26. Ldc gvo D:1 + vin Cd - + vd - gvd Co g=φ(4π-3|φ|)/18πωLs Figure 3.26 Equivalent circuit of average model 51 + vo - RL To obtain a linear small signal model, add perturbation around the operating point, and the small signal equation can be calculated after remove DC part and higher order nonlinear terms. In terms of (3.46), the small signal model could be developed as follows: diˆ Ldc vˆ in Dvˆ d V d Dˆ L dc dt (4 3 ) Vo (4 6 ) dvˆ d ˆ vˆ d DiˆLdc I Ldc Dˆ C d 18 Ls 18 Ls dt dvˆ o (4 3 ) V d (4 6 ) vˆ ˆ vˆ d o C o 18 Ls dt RL 18 Ls (3.49) Based on (3.49), the equivalent small circuit model is developed in Fig. 3.27. Ldc + ^vin ^ VdD + - D:1 ^ ILdcD m1φ^ Cd ^ g1vo ^ g2vd m2φ^ + ^vd - - ^ vo Co + RL - Figure 3.27 Equivalent small signal circuit model In Fig. 3.27, g1=g2=(4π-3|φ|)φ/18πωLs, m1=(4π-6|φ|)Vo’/18πωLs, and m2=(4π6|φ|)Vd/18πωLs. Vo’ is the dc-link voltage on HVS referred to the LVS, and RL is an equivalent load resistance of the output port, RL = Vo’2/Po.= .18 πωLs /(4π-3|φ|)φ. The equation (3.44) can be written as space state equations in (3.50): dXˆ A Xˆ B Uˆ , Yˆ C Xˆ dt (3.50) Where, 0 iˆLdc D ˆ X vˆd , A Cd vˆo 0 D Ldc Vo (4 3 ) C d 18L s (4 3 ) C o 18L s 52 0 1 Co RL 0 vˆin ˆ U Dˆ , ̂ 1 Ldc B 0 0 Vd Ldc I Ldc Cd 0 Vo (4 6 ) Cd 18 Ls Vd (4 6 ) Cd 18 Ls 0 The output Yˆ can be obtained as: vo (s) C1 (sI A)1 BU (s) , C1 [0 0 1] (3.51) According to (3.51), the control-to-output transfer function can be derived as: Gv ( s) mR L In (3.52), the term s / 0 2 2s / 0 1 s 1 1 / C o RL s2 1 2 D / C d Ldc s 2 2 D /g L R dc L (3.52) s is very small, so it can be ignored, and the transfer function D / g 2 Ldc RL 2 becomes: Gv ( s) mR L s / 0 2 2s / 0 1 s 1 1 / C o RL s2 1 2 D / C d Ldc (3.53) There are a pair of conjugated right half plane zeros, so the stability criterion is Фm = -2×180° +180°+∠Gvφ(j2πfc) > 0, where fc is the crossover frequency. The parameters of the system are listed below: Vin = 24~48V, D = 1/3~2/3, φ = 8π/180, Vd = Vo’ = 72V, fs = 40kHz, Ldc = 7.5uH, Ls = 510nH, Cd = 5600μF, Co = 3120uF, RL = Vd φ (4 π-3 φ)/(18 π ω Ls). In transfer function Gvφ(s), The zeros and poles are located at: z1,2 = 0.0128 ± j1625.5, and the poles are located at: p1,2 = -0.01253 ± j1627.5, and p3=-19.02. Because the two poles and two zero are very close and far away from origin and the main pole is p3, the magnitude curve of transfer function is just like an integral but the phase angle has –(360+90)° delay at ω=∞. The open loop bode plot of control to output transfer function Gvφ(s) is shown in Fig. 3.28. The crossover frequency is fc = 5.94 kHz, and Фm = -270.4° < 0. 53 Gvφ(s) Bode Diagram Magnitude (dB) 150 D=1/3 D=1/2 D=2/3 100 50 0 -50 360 Phase (deg) 270 180 90 0 -90 -1 10 0 10 1 2 10 10 3 10 4 10 Frequency (Hz) Figure 3.28 Bode plots of control to output Considering the change of input voltage Vin, the duty cycle is regulated to maintain the LVS dc-link voltage Vd constant. The transfer function of duty cycle to dc-link voltage can be developed by: vd (s) C2 (sI A) 1 BU (s) , C2 [0 1 0] (3.54) The transfer function Gvd_d(s) is: s LdcVd g / D 3 1 s1 1 / C R o L Gvd _ d ( s) s s2 1 2 1 1 / Co RL D / Cd Ldc 54 (3.55) 3.6.2 Control system design In order to keep the output voltage constant, an output voltage controller is designed to make the system stable. The compensator Gvc(s) consists of a PI and a lag compensator, which is, 5(1 0.00083 s)(1 0.0073s) s(1 0.003s) Gvc ( s) (3.56) After the compensation, Фm becomes 45.2°, but the bandwidth decreases to 110Hz.This is because that the crossover frequency of the open-loop gain is severely restricted by the right half-place zeros. If higher closed-loop performance is necessary, the multiloop control scheme can be considered. Gvφ(s)Gc(s) Magnitude (dB) 100 Bode Diagram D=1/3 D=1/2 D=2/3 50 0 fc=110Hz -50 -100 270 Φm=45.2º Phase (deg) 180 90 0 -90 -180 0 10 1 10 2 10 3 10 Frequency (Hz) Figure 3.29 Bode plots of voltage loop gain with compensator 55 4 10 3.7 Experimental Results A 6kW experimental prototype is built in the lab, and the specification and parameters of converter are listed in Table IV. The input voltage varies from 24V to 48V, and output voltage is 288V. Fig. 3.30 shows a photo of 6-kW prototype with a liquid-cooled heat sink. The size of this converter is 13.7″ by 7.8″. The DC inductors and transformers are implemented with PCBs and 6 E64-3C92 planar cores. Fig. 3.31 is the control diagram including current sharing controller. The duty cycle D is just controlled to keep LVS DC-link voltage constant, and phase shift angle is used to control the output voltage. The duty cycle D and phase shift angle is used to control the output voltage. Table 3.4 Specifications and parameters of converter Input voltage Vin (V) 24~48 Output voltage Vo (V) 288 Rated power Po (W) 6000 Switching frequency fs (kHz) 40 LVS MOSFETs SK 260MB10 LVS Snubber 0.2 µF HVS MOSFETs ST W45NM50FD HVS Snubber 30 nF LVS Capacitor 5600µF + 10 µF*25 (MLCC) HVS Capacitor 390 µF + 10 µF*5 (Film) HF Transformer E64-3C92*6 DC Inductor E64-3C92*6 56 GND +Vin Low Voltage Side High Voltage Side DC inductor Transformer Figure 3.30 Photo of 6kW experimental prototype + + - - PI PI ÷ × Tper1 φa φb Fig. 3.18 φc φ0 + Sa1 D Tper2 φbS s1 φb D + Sb1 Tper3 Sc1 D0 φa Sr1 φa D φc St1 φc Sa1 ia,b,c Vo Sa1 Sb1 Sb2 Sc1 3-phase Sc2 Sr1 DC-DC Sr2 converter Ss1 Ss2 St1 St2 Vd Vin D PWM generator Figure 3.31 System control system including current sharing controller 57 Fig. 3.32 shows the transformer current with different duty cycle. The current become 2 level waveforms in D = 1/3, 2/3, which are the same as 3DHB converter. Fig. 3.33 shows the DC inductor current and total input current with D = 1/3, 1/2 and 2/3, respectively. The large DC inductor current ripple of each phase is benefit for device ZVS operation and lower inductor volume size but a total small current ripple can be achieved by interleaving three-phase current. It can be seen that when D = 1/3 and 2/3, the input current ripple is minimum, and when D = 1/2, the current ripple reaches maximum value. As shown in Fig. 3.34, the ZVS is always guaranteed in the switches of LVS in the light load under varied input voltage. Fig. 3.35 shows that when the input voltage changes from 24V to 48V, duty cycle is changed with the input voltage Vin and satisfies D = Vd/Vin. The measured efficiency from 450W to 4.5kW with different input voltage is shown in Fig. 3.32. The efficiencies in different input voltage keep stable, and the highest efficiency is 96.4% at Vin = 36V and Po = 2.3kW. 58 Idc_total(20A/div) Idc_a Idc_b Idc_c (10A/div) (a) Idc_a Idc_b Idc_c (10A/div) Idc_total(20A/div) (b) Idc_a Idc_b Idc_c (10A/div) Idc_total(20A/div) (c) Figure 3.32 Three-phase inductor current and total input current: (a) Idc at D = 1/3, (b) Idc at D = 1/2, (c) Idc at D = 2/3 59 Isa, 3.8A/div Isb, 3.8A/div Isc, 3.8A/div (a) Isa, 3.8A/div Isb, 3.8A/div Isc, 3.8A/div (b) Isa, 3.8A/div Isb, 3.8A/div Isc, 3.8A/div (c) Figure 3.33 Transformer current on secondary side with different D (a) D = 1/3; (b) D = 1/2; (c) D = 2/3 60 Vds_a1 20V/div Vgs_a1 10V/div Vds_a2 20V/div Vgs_a2 10V/div Vds_a2 20V/div Vgs_a2 10V/div (a) Vds_a1 20V/div Vgs_a1 10V/div (b) Vds_a1 20V/div Vgs_a1 10V/div Vds_a2 20V/div Vgs_a2 10V/div (c) Figure 3.34 ZVS waveforms for Sa1 and Sa2 at Po=1200W in (a) Vin=24V; (b) Vin=36V; 61 (c)Vin=48V 288V Vo 50V/div 72V 48V Vd 20V/div 24V Vin 10V/div 7.65A Io 5A/div η/% Figure 3.35 Voltage and current waveforms when Vin varies between 24V and 48V Po/W Figure 3.36 Measured efficiency of proposed converter at Vin = 24V, 36V and 48V 3.8 Summary This chapter proposes a three-phase current-fed bidirectional isolated DC-DC converter to achieve high efficiency over a wide input voltage range. By using proposed technology, the reactive power loss is always maintained to be low and ZVS conditions can be maintained when 62 input voltage changes, so high efficiency can be guaranteed over a wide operation range. Another feature of the proposed topology is to allow the small passive components while the current and voltage ripples can still keep small due to three- phase interleaving structure. The maximum input current ripple is no more than 20% of total input current. With respected to the leakage inductance unbalance ratio, the proposed topology with Y-Y connected transformers decreases the current unbalance ratio by half. Although Δ-Δ type topology achieves the similar performance, the phase current and transformer current cannot be regulated to balance at the same time. In addition, PCB planar transformers are applied to achieve the lower profile and better consistency compared with conventional transformers. Finally, both the power loss calculation and the experimental results based on a 6-kW optimal designed prototype validate the effectiveness of the proposed topology. 63 CHAPTER FOUR INTEGRATED THREE-PORT THREE-PHASE DAB DC-DC CONVERTER 4.1 Introduction DC distribution energy systems (DES) have the advantages to interact with renewable energy source due to the simplicity and efficiency [1]. DES include but are not limited to photovoltaic (PV), fuel cells, which generate DC voltage, and wind turbine, microturbine and internal combustion engines (ICE), which generate AC voltage. All of these DE resources have to be interfaced with a DC bus and feed power to the load or the utility grid, therefore dc-dc or ac-dc power electronics converters are essential units [2-7]. Moreover, many energy storage systems, for example batteries, super capacitors and flywheels, are considered to be installed in DES to provide dispatchability of their distributed resources which are renewable energy sources, like solar and wind power without dispachability by their own. Proper sizing selection of the renewable energy source can meet the energy requirement, and the energy storage system can balance the difference between the renewable energy source and the load requirement. It also helps intensive penetration of renewable energy production such as PV into the grid by proposing peak shaving service at the lowest cost [1, 8-10]. The similar power electronics converters are necessary to interface energy storage elements to the grid or load. A common DC distribution bus shared by these converters is an effective solution, since the total number of converters is lower compared with the ac solution, even if it is necessary to have an ac-dc interface converter with the utility grid [7]. Dc-dc converters have got a fair amount of use in DES. Compared to the individual twoport dc-dc converter, integrated multi-port dc-dc converter is a popular topic for its less components, higher system efficiency and easier centralized control. This paper is focused on DC distribution system for PV applications, which is shown is Fig. 4.1. In DC distribution system, a basic cell of DES consists of an energy source (PV panels), and an energy storage element such as batteries. The PV panels and batteries are widely of utilization due to the decrease of the costs. Multi-port dc-dc converter as an attractive solution is suitable to integrate the PV and energy storage element with the advantages of high efficiency, high power density 64 and cost-effective, which has been addressed in various literatures. In [11-12], a three-port converter is proposed to interface with PV and batteries. However, the presented converter is not able to charge the battery from common dc bus side due to the unidirectional power flow between primary side and secondary side. Moreover, the power control of PV and battery is coupled so that a decoupled controller should be designed. Another popular topology is the three-port transformer coupled dual-active-bridge (DAB) converter for renewable energy system application which is addressed in [13-17]. Since it is magnetic coupled, all of three-port are galvanic isolated and the bidirectional power flow. In this topology, since only one multiwinding transformer is applied to interface with three half or full bridges, there exists circulating current in the three-port dc-dc converter. How to minimize the circulation power loss is another issue for this type of topology [16, 18]. An interleaved triple-voltage dc-dc converter is discussed in [19], which consists of two half-bridges and a high-frequency transformer to provide voltage level matching and galvanic isolation. The interleaved structure is to reduce the capacitor requirement and current ripple. A low cost, soft-switched bidirectional dc-dc converter for connecting the three voltage nets is discussed in [20]. Based on this topology, an interleaved reduced-component-count three voltage bus dc-dc converter is proposed for fuel cell electric vehicle applications to reduce the capacitor requirements and current ripple [21]. The dc inductor is removed, but it is not easy to realize the power flow management between two low voltage ports. Since the voltage is fixed in these applications [19-21], the duty cycle is set to around 1/3 and varied duty cycle control is not analyzed, the power flow between two low voltages ports is not mentioned neither. Therefore, it can be expected that when the duty cycle control is applied, the power flow management will be flexible. On the other hand, the soft-switching conditions and controller will be affected, which are necessary to be investigated. 65 Utility Grid AC AC/DC DC DC Distribution Bus DC Load DC/DC DC/DC PV Panel Energy Storage System DC/DC DC Load PV Panel DC/DC Energy Storage System Figure 4.1 A DC distribution system with basic cell for PV applications: Energy sources, Energy storage element and Load In this chapter, a three-port bidirectional dc-dc converter for PV system applied on DC distribution is proposed. The PV panels are connected to the current source port to meet the maximum power point tracking (MPPT) and voltage variation requirement. The battery pack is connected to the low voltage side (LVS) dc-link due to the relative constant voltage. The DC distributed bus is connected to the high voltage side (HVS) port to realize galvanic isolation by high frequency transformer. Compared to the single-phase dual-half-bridge (DHB) and DAB converters, the three-phase interleaved structure reduces passive components size, current and voltage ripples. ZVS can be guaranteed in different operation mode even PV voltage varies in a wide voltage range and battery voltage change in small voltage range due to different state of charge (SOC) and charge/discharge status. In addition, the three-port power flow control is natural decoupled in a wide operation range, so it can be treated as a conventional two stage dcdc converter which consists of a boost converter and a three-phase DAB converter. Therefore the 66 controller can be easily designed separately that the boost circuit part is for MPPT and voltage step up functions and isolated DAB circuit is for interface with battery and dc distribution bus. 4.2 Converter Description Fig. 4.2 shows the proposed integrated three-port dc-dc converter topology. A threephase DAB converter is applied to realize the bidirectional power flow function and the Y-Y connected high frequency transformers can provide galvanic isolation and voltage-level matching between low voltage energy sources and high voltage dc bus [22]. The leakage inductance of transformer Ls1~Ls3 is as energy storage elements to transfer the power between two sides and the power flow is mainly controlled by a phase-shift angle φ. The middle points of three legs in LVS are connected to one energy source port through three dc inductors Ldc1~Ldc3, and duty cycle D is another control variable to adjust the power distribution between the two ports of LVS. In the application of PV system on dc distribution bus, the converter is applied to interface with PV panels, battery unit (BU) and dc bus or load. BU as an energy storage element is connected to the LVS dc-link. The voltage of battery changes slowly with different SOC, so the primary side dc-link voltage can keep constant. The PV panels as energy sources are connected to the current source port. The output voltage and current of PV change in a large range due to different solar irradiation and ambient temperature. Three-phase dc inductors and primary side switches are used to boost the PV voltage and MPPT can be realized by the duty cycle control. With the help of dc inductors, ZVS is guaranteed in all operation modes even though the battery’s voltage changes with different SOC. Compared to the single-phase topology, three-phase interleaved topology can reduce the current and voltage ripples so as to reduce the inductor and capacitor’s size. 67 Three-port integrated DC-DC converter i2 Primary dc link 1:n Secondary dc link = i3 P2 Port II (BU) i1 V2 C2 P1 Port I (PV) Sr1 Sa1 Sb1 Sc1 Ldc1 a Ldc2 b Ls2 Ldc3 Ls3 C1 V1 Sa2 c Sb2 Ls1 St1 V3 r s t Sr2 Sc2 Ss1 Ss2 C3 P3 Port III (DC Bus/ Load) St2 Figure 4.2 Three-port integrated bi-directional dc-dc converter The modulation strategy of the three-port is similar to that of two-port DAB3 converter, so the operation principle can be referred to that in [22]. It can be seen that the converter can be divided into six operation area and the power flow between two sides will change according to different combination of duty cycle and phase-shift angle, which is shown in Fig. 4.3. In practice, in order to operate converter to achieve high efficiency, the duty cycle is limited between 1/3 and 2/3, and the phase-shift angle should be smaller than π/3 for low reactive power loss. For example, when the converter is mainly operating in Area III, the power equation is given as [22]: (4.1) Where V3’ is the HV bus voltage referred to the LV side, and V3’= V3/n. The phase-shift angle φ can be calculated as: (4.2) 68 φ IV II V I VI III D 2/3 1/2 1/3 VI I V II IV Figure 4.3 Six operation areas with different duty cycle and phase-shift angle, and shadowed part is the practical operating area Three-port Converter P3 P2 P1 P3 P2 P1 (A) P3 P2 P1 (B) P3 P2 P1 (C) P3 P2 P1 (D) (E) Figure 4.4 Operation modes in different power flow. (A) P1>0, P2<0, P3<0; (B) P1>0, P2>0, P3<0; (C) P1>0, P2<0, P3>0; (D) P1=0, P2<0, P3>0; (E) P1=0, P2>0, P3<0; The operation modes of three-port converter can be distinguished by the power flow combination, which are listed in Table I. Since the PV panels cannot sink power, there are five operation modes. Fig.4.4. shows the operation modes in different power flow, P1, P2 and P3 represent the power from the corresponding three ports, and the positive power means that the power is generated from the port. Due to the power conservation law, the power satisfies 69 (4.3) Table 4.1 Operation modes in terms of different power flow Mode A Doesn’t exist Mode B Mode D Mode C Mode E Doesn’t exist Doesn’t exist In mode A, when the solar irradiation is high, PV can provide power to the DC bus and charge the battery at the same time. According to different power management strategy, the objective of power control can be the battery’s charging current Ibat or the scheduled DC bus current Ibus. (4.4) In this mode, the BU functions as an energy storage element to store the excess energy. The bolded part is the control objective. In mode B, when the solar power is not high enough, PV with BU together will provide power to meet the scheduled DC bus load requirement, and the bus current Ibus is the control objective, (4.5) In this mode, the BU functions as an energy source to support the DC bus load. In mode C, when SOC of battery is low, PV and DC bus will provide power to charge the battery. 70 (4.6) Since the constant charging current is preferred, the DC bus power is used to make it constant and mitigate the disturbance resulted from the PV power. In mode D, when there is no solar power in the evening or cloudy days, the power from DC bus can charge the battery. (4.7) This mode is used to save the grid energy into the energy storage system when the utility price is low at night or there is excessive power generated from other energy source. The optimized power management strategy is out of scope here, so the mode sequence optimization will not discuss in this paper. In mode E, when there is no PV power, battery can discharge to meet the requirement of DC bus load. (4.8) This mode mainly happens in the stand-alone mode and there is no other energy source available to support the load. The BU functions as a back-up energy source to provide uninterruptable power. There are other operations modes in which solar power is only to charge the battery or solar power is only to support the DC bus load, but they are not common and can be avoided with proper power management strategy. 4.3 ZVS Conditions Analysis The soft-switching condition of three-port topology is different from that of two-port case [22], because the power generated or sunk from energy storage element will have influence on the switches’ current on primary side. Hence the ZVS analysis is necessary and described in the following section. The natural soft-switching is the characteristic of DAB3 when the dc-link voltages on both sides are matched. For three-port dc-dc converter in PV application on dc distribution 71 system, the ZVS conditions should be calculated in different operation mode. The ZVS conditions will be also affected by the voltage variation due to the battery’s voltage changes with the SOC. 4.3.1 Pseudo “two-port” ZVS Analysis When PV does not provide power, it becomes two-port converter soft switching analysis. However, this two-port soft switching is different from that of two-port in [23], because in [23] the power in primary side is generated from current source port and in this paper the power is provided from battery which is connected to the primary side dc-link. It is also different from that of DAB3 converter in [22] because there is existing dc inductor current in primary side which will change the current waveform in switches, thus affecting the ZVS conditions. Therefore, it is defined as pseudo “two-port” ZVS condition in this paper. In the DC distribution system, the voltage variation of battery due to the state of charge (SOC) should also be considered. When the primary side dc-link voltage changes according to the SOC of battery, the d=V3’/V2 will change around 1, which is shown in Fig. 4.5. During discharging, the battery’s voltage will decrease and d is higher than “1”. During charging, the battery’s voltage will increase and d is lower than “1”. However, with the help of dc inductor current ripples, the ZVS can be guaranteed when d is changing (0.9~1.1). Define m=iLdc/iLs, the dc inductor current ripple of each phase can be calculated as, (4.9) The ZVS conditions of the switches for one phase should satisfy the inequation (4.10): (4.10) According to (4.10), the constraint conditions of ZVS related to d can be derived. Because in different operation areas, the transformer current is different, the ZVS conditions should be calculated separately. In practice, the converter is mainly operating in the area of ∈ , and the expressions of power and current can be calculated in corresponding operating Area II, III and V. The detailed calculation for Area III is shown here. For instance, in the range of d should satisfy (4.11) to meet the ZVS conditions, 72 (4.11) The worst case happens when φ is 0, (4.12) In DAB3 converter, only “d = 1” can meet the requirement at the point φ = 0. Compared to DAB3 converter, the ZVS range is enlarged in the primary side. In practice, the battery’s voltage will vary with different SOC and charge/discharge status. Fig. 4.5 shows the battery’s voltage curves during charging and discharging, and d varies around “1” by selecting proper rated value of V2 and V3. Based on (4.11), the ZVS boundaries are plotted in Fig. 4.6. In Fig. 4.6, the converter is operating in the shadowed area. d is changed between the values in the worst case due to the variation of battery’s voltage, i.e. d is 0.9 in charging mode and 1.1 in discharging mode. It can be seen that the operation curves are always located between the upper and lower ZVS boundaries so that soft-switching can be guaranteed in the whole operating range. VB d=V3'/V2 Discharge Curve (V) d VB Charge Curve (V) d<1 VB_up VB0 VB_low VB_up 0.9 d=1 VB_low 1.1 d>1 60% 80% Discharge Performance (0.2C) 100% 80% Charge Performance (0.2C) Figure 4.5 Battery’s voltage in charge/discharge performance 73 60% 2.1 2.1 ZVS boundary with dc current ripple ZVS boundary for DAB3 1.9 1.9 d=V2'/V1 1.7 1.7 1.5 1.5 ZVS upper boundary 1.3 1.3 d=1.1 1.1 1.1 Mode E, battery discharging (d>1) 0.9 0.9 Mode D, battery charging (d<1) d=0.9 0.7 0.7 0.5 0.5 ZVS lower boundary -1 -1 -0.8 -0.8 -0.6 -0.6 -0.4 -0.4 -0.2 -0.2 0 0 φ/rad 0.2 0.2 0.4 0.4 0.6 0.6 0.8 0.8 1 1 Figure 4.6 ZVS boundaries in pseudo “two-port” mode 4.3.2 ZVS conditions in three-port mode In three-port mode, the soft-switching is not only related to dc inductor current but also related to the PV power. Define the PV power , and then the average PV current of each phase is, (4.13) According to different power flow direction, the inequations should be satisfied in all the three cases: (4.14) 74 According to (4.14), the ZVS conditions of each switch in Area III can be calculated as, (4.15) So the general ZVS condition is: (4.16) In the worst case when φ is 0: (4.17) In (4.17), it can be seen that if the Ppv is large enough to make d<1, there will always be hardswitched when φ is 0. The solution of d exists only when (4.18) Based on (4.18), ZVS can be guaranteed by selecting proper m. According to (4.16), the ZVS boundaries are plotted in Fig. 4.7. In Fig. 4.7, the d is set to the worst case value due to the variation of battery’s voltage and n is 0.1 which is half of the rated power. The operation curves are located between the upper and lower ZVS boundaries except Mode A when phase-shift angle is small and d is less than 1, but the ZVS range is still improved compared to that of DAB3 converter. 75 2.2 2.2 ZVS boundary with dc current ripple 2.02 ZVS boundary with dc current ripple and n=0.05 1.8 1.8 1.6 d=V2'/V1 1.6 ZVS upper boundary 1.4 1.4 1.2 1.2 d=1.1 Mode B, battery discharging (d>1) 1 Mode C, battery charging (d<1) 1.0 d=0.9 0.8 Mode A, battery charging (d<1) d=0.9 Hard switching 0.8 ZVS lower boundary 0.6 0.6 -1 -1 -0.8 -0.8 -0.6 -0.6 -0.4 -0.4 -0.2 -0.2 0 φ/rad 0.2 0.4 0.6 0.8 0.8 11 Figure 4.7 The key current waveforms in different operation modes 4.3.3 ZVS Conditions in General Case In general case, the ZVS conditions of each switch is rewritten here, (4.19) Where the dc inductor current changes with time, (4.20) 76 and transformer current will change with different operation area. Since in steady state the average transformer current is zero and voltage-second balance should be satisfied, the transformer current at the time tSa1_on can be calculated, (4.21) The transfer current at other time can be calculated in the same way. When and is negative, are exchanged. The dc inductor current ripple is (4.22) Where . The average dc inductor current can be calculated by (4.23) Since the rated power of the converter is at , (4.24) In order to maintain the high efficiency and lower reactive power, selected as , the rated power should be not high. If is is, (4.25) The PV power should be less than , i.e. n<0.2. Substitute (4.20)-(4.23) into (4.19), the ZVS conditions in different case can be calculated and summarized in Table 4.2. According to Table 4.2, it can be seen that the ZVS range changes with help enlarge ZVS range but reduces it. If and . can , the converter can operate with ZVS at , which can be derived, (4.26) 77 Table 4.2 ZVS Conditions in Different Operation Area Operation ZVS Conditions ZVS Condition at Area II III V Where 4.4 Control System Design Since the power between the primary side and secondary side in Area III (1/3<D<2/3, φ<2π(D-1/3), φ<2π(2/3-D)) is: (4. 27) Different from the single phase DHB converter [24] and DAB converter [15], it is just related to the phase-shift angle φ but has no relation to D. The three-port converter can be treated as a three-phase boost converter with duty cycle control connected to a three-phase DAB converter with phase-shift angle control which is shown in Fig. 4.8. It becomes a conventional two stage DC-DC converter, and the controller includes boost controller and DAB controller with fixed duty cycle. Fig. 4.9 illustrates the controller for two converters. 78 Three-phase Boost Converter i12 DAB3 Converter i23 iin_DAB3 Primary dc link 1:n Secondary dc link io_DAB3 i3 Sw i1 Port I (PV) Su1 Sv1 1 Ldc1 u Ldc2 v Ldc3 w Su2 Sv2 i2 Sa1 V2 C2 Port II (BU) Sw Sa2 Sb1 a Sr1 Ss1 Sc1 Ls1 b Sb2 r Ls2 c St1 V3 s C3 t Ls3 Sr2 Sc2 Ss2 Port III (DC Bus) St2 2 Figure 4.8 The equivalent circuit of three-port dc-dc converter H1(s) i1 PV model v1 Sin Tin MPPT Controller (P&O) i3a* p pv + ibu vb u SOC Controller ibu* vbu* pbat * ÷ v3 + Mode sw i pv D Ci(s) - i3 Gid_boost(s) φ i3 Giφ _DAB(s) H2(s) i3b* Figure 4.9 Control system diagram For three-phase DAB converter, since there are 12 sub-periods in one switching cycle, it is much more complicated to derive the full-order small-signal model than that of full-bridge DAB converter [25-26]. According to the power equation (4.27), the average state equation can be written as: (4.28) 79 Where , , and Re is the equivalent DC load resistance. The small signal model can be derived by expanding the average model into Taylor series around the operating point, and then neglecting the higher order nonlinear terms, which is described as follows: (4.29) Where , , The output current to control transfer function can be derived (4.30) A converter with proposed topology was built in the laboratory. In order to design the controller for this converter, the parameters are listed in the Table 4.3. The duty cycle D is controlled by the MPPT controller, and the phase-shift angle control is implemented by the compensator , which is expressed as: Table 4.3 Three-port Converter Parameters DC bus voltage V3 270V Battery voltage V2 67.5V PV voltage V1 32~42V Rated power P3 2kW Switching frequency f 40kHz Transformer turns ratio 1:4 Leakage inductor Ls 1µH DC inductor Ldc 7.5µH Input capacitor C2 5600µF DC-link capacitor C3 780 µF 80 (4.31) Where . After compensation, the cross frequency of current open loop is 1.69kHz and the phase- margin is , which is shown is Fig. 4.10. The average model of the three-port dc-dc converter is developed for verification of operation mode simulation. Based on the equivalent circuit, the converter can be divided into two stages: boost stage and DAB3 stage. According to (4.19), the average model can be derived, which is shown in Fig. 4.11. Bode Diagram Magnitude (dB) 100 50 0 -50 Phase (deg) -100 0 -45 -90 -135 -180 101 102 103 104 Frequency (rad/sec) 105 Figure 4.10 Current open loop gain of DAB3 stage built in the laboratory 81 106 C1 Ldc I1 DV2 DI1 C2 PV Model V2 + - gV3' gV2 C3' Io' V3' + - + DAB3 Converter Boost Converter g=φ(4π-3|φ|)/6πωLs Figure 4.11 Average model of three-port dc-dc converter IoA i iIoB O2 Dutyavg 1 D D2Duty1 D3 φ1 phiavg*180/3.14 2 3 Ioavg O1 iO3 22 20 20 18 18 16 16 14 14 12 12 10 10 8 8 Io(A) 22 Duty Duty 4 0.64 2 0.62 .6 0.6 8 0.58 6 0.56 4 0.54 phiA*180/3.14 φ φ φ(◦) 0.1 phiB*180/3.14 1,3 60 50 50 40 40 30 30 20 20 10 10 60 0.15 2 0.2 0.25 0.3 0.35 Time(s) Figure 4.12 Simulation results comparison: 1, Circuit model; 2, Equivalent circuit model; 3, Average model The comparison of three-port converter, the equivalent circuit and the average model are simulated and displayed in Fig. 4.12, in which the load power changes from 4150W to 6150W at 0.2s and changes back to 4150W at 0.25s, and the PV voltage changes from 32V to 42V with a finite slope. In the equivalent circuit, the duty cycle D of DAB3 stage is fixed 0.5. 82 The simulation results show that the three models are almost consistent with each other. The difference happens at when the output current is high and input voltage is relatively large. Since in this condition, the converter is operating in Area V which has different power equation [23], i.e.: (4.32) Under this condition, the controlled phase-shift angle is not consistent with each other. Considering that difference of power equation in Area III and V is no more than 10%, the average model derived from Area III can still be applied approximately in the whole operation range. Fig. 4.13 shows the one day scaled down simulation results of proposal controller based on the average model. In Fig. 4.13, from 0s to 6s, there is no solar power, and the DC distribution bus provides power to charge the battery, so the converter is operating in Mode D. At 6s, solar irradiation starts to increase from 200W/m2 to 1000W/m2. From 6s to 7s, the PV with DC distribution bus together generates power to charge the battery, and the converter is operating in Mode C. At 7s, there is a peak power requirement on DC distribution bus side, and PV and battery provide power to the DC bus load. The converter operates in Mode B when the PV power is lower than the DC bus load requirement, and operates in Mode A when the PV power is higher than DC bus load. At 18s, there is another peak power requirement from DC bus side, and the battery provides main power due to the low solar irradiation level. After 19s, the solar power is zero, and the DC bus load is supported by the battery, so the converter is operating in Mode E. From Fig. 4.13, it can be seen that when the irradiation changes, only duty cycle is controlled to realize the MPPT. Phase-shift angle only changes when there is power flow response between the two sides such as variation of battery’s charging current or DC load current. 83 D Sin(W/m2) Mode 1500 1500 C B Night A B E Day time Night 1000 1000 1000W/m2 500 500 00 0 6 12 18 (a) 24 18 (b) 24 PPV(W) 4000 4000 2150W 2000 2000 00 0W 0 ibat(A) 50 50 6 12 10A 10A 00 -20A -61A -50 -50 -100 100 0 6 12 18 i3(A) 20 20 5A -2.5A 00 -10 -10 15A 10A 10 10 0 6 12 18 φ/rad 0.2 0.2 0.148rad 0.047rad -0.023rad 00 0 6 12 D 0.6 18 (e) 24 18 18 24 24 (f) 0.55 0.47 0.5 0.5 0.4 0.4 (d) 24 0.096rad 0.1 0.1 -0.1 -0.1 (c) 24 00 66 12 12 t(s) Figure 4.13 One day simulation results using average model 84 4.5 Experimental Results A 3kW three-port DC-DC converter is developed for experimental verification. The parameters of the system are the same as those in the simulation, which are listed in Table 4.2. In the experiment, the PV panels are emulated by a 4kW, 50V, 80A PV emulator, and the parameters of PV panels are listed in Table 4.3, which is referred to the Sunpower 215 PV panel. Five U27-12RT 12.8V lithium iron magnesium phosphate (LFMP) battery modules in parallel are used as an energy storage element. Fig. 4.14 and Fig. 4.15 show the discharge and charge performance of the battery, respectively [27]. It can be seen that the voltage range is [12.9V, 13.4V] during discharging with 0.2C and [13.6V, 14.6V] during charging status. So the rated primary side DC link voltage can be set to 13.5V*5 = 67.5V, and the range of d is [0.956, 0.99] in discharging mode and [1.01, 1.08] in charging mode, which is satisfy the ZVS conditions mentioned in section 4.4. Table 4.4 Parameters of PV panel Sunpower 215 (25◦C, 1000W/m2) Max. Power Voltage (Vpm) 39.8 V Max. Power Current (Ipm) 5.40 A Open Circuit Voltage (Voc) 48.3 V Short Circuit Current (Isc) 5.80 A Module Efficiency 17.3% Peak Power (Pmax) 215 W Power Coefficient -0.38%/K Voltage Coefficient -136.8mV/K Current Coefficient 3.5mA/K 85 x 13.4V x 12.9V Figure 4.14 Discharge performance of one battery module x 14.6V 13.6V x Fig. 4.15 Charge performance of one battery module The experiment set up is shown in Fig. 4.16. The PV parameters are set in PPPE software and interface with PV emulator via USB communication. Fig. 4.17 shows the V-I characteristics and that the maximum power point (MPP) can be tracked when MPPT method is applied in the threeport DC-DC converter. 86 PC Interface (PPPE) Battery Packs 13.5x5=67.5V Comm Cable DC Load PV Panel 4kW Magna PV Emulator 3-port DC-DC Converter Figure 4.16 Experimental set up Maximum Power Point 28.0 800W/m2 24.0 20.0 Ipv/A 16.0 12.0 8.0 4.0 0.0 0.0 10.0 20.0 30.0 40.0 50.0 Vpv/A Figure 4.17 V-I characteristics curve for five PV panels in parallel Fig. 4.18 gives a time scale down one day performance of the three-port converter. In the morning the solar irradiation begins to increase, so the PV current increases and the battery’s current decreases. There is one load peak period during the morning, and battery with PV 87 together will provide power to the load, where the converter is running in Mode B. When the PV power is higher than load power, the excess power is charging battery, where the converter is in Mode C. In the afternoon, the irradiation begins to decrease from 1000W/m2 to 150W/m2, it can be seen that the PV current is decreasing with the same trend and the MPPT is always satisfied. In the evening, the PV current is 0, and the DC load is supported by battery, where the converter operates in Mode E. Fig. 4.19 shows the Vds and Vgs voltage waveforms on Sa2 in three different Modes, since the lower switches on LVS are hardest to achieve ZVS conditions. It can be seen that, before Vgs increases, the Vds has decreased and the anti-parallel diode is conducting, so the Sa2 is zero voltage turn-on. vo (50V/div) vpv (10V/div) vbat (10V/div) ipv (5A/div) ibat (5A/div) io (2A/div) Evening Mode B Morning Afternoon Mode C Mode B Evening Mode E Figure 4.18 One day scale down experimental results 88 (a) (b) (c) Figure 4.19 ZVS waveforms of Sa2 in different operating modes: (a) mode B; (b) mode C; (c) mode E 89 4.6 Summary In this chapter, a three-port PV system with energy storage for DC distribution system using three-phase interleaved bidirectional dc-dc converter was proposed. The high frequency transformers provide voltage boost capability and galvanic isolation. PV and battery interfacing with different type of ports can realize MPPT and soft switching under wide variation of PV voltage. The soft switching can be guaranteed in most of operation mode even the battery’s voltage changes due to the different charge/discharge status. The two control variables, duty cycle and phase shift angle, can be controlled independently to realize MPPT and power flow between energy sources and load. The benefit of bidirectional power flow is helpful to manage the SOC of battery in grid connected mode. Simulation and experimental results verified the principles. 90 CHAPTER V CONLUSION AND FUTURE WORK 5.1 Conclusions In the presented work, an interleaved three-phase current-fed bidirectional DC-DC converter for hybrid electric vehicle application is investigated. Based on the literature survey of several low voltage high current bidirectional DC-DC converters, current-fed bidirectional dc-dc converters are selected as candidates for hybrid. The three-phase interleaved structure is helpful to reduce the current and voltage ripple or reduce the capacitor and inductor sizing. The maximum input current ripple is no more than 20% of total input current even when the phase current ripple is as high as the rated current value. In this work, it is first proved that three-phase DAB converter has lower reactive power than singlephase DHB converter or full-bridge DAB converter. It also reveals in this work that Y-Y transformer connection type converter can provide inherent current sharing capability compare to other type of transformer connection. The phase shift angle and duty cycle control are employed in the converter to realize the power flow control and soft-switching in wide voltage range, which is suitable for renewable energy sources or super capacitors. The operation principle of three-phase bidirectional dc-dc converter is thoroughly analyzed in this thesis, and the soft-switching condition is also derived in different operation mode. The analysis is necessary for hardware design and optimization. In addition, by using phase shift and duty cycle control, the reactive power loss is always maintained to be low and ZVS conditions can be satisfied when input voltage changes, so high efficiency can be guaranteed over a wide operation range. A three-port PV system with energy storage for DC distribution system using three-phase interleaved bidirectional dc-dc converter was proposed in this work. The high frequency transformers provide voltage boost capability and galvanic isolation. PV and battery interfacing with different type of ports can realize MPPT and flexible power management. The soft switching can be guaranteed in most of operation mode even the battery’s voltage changes due to the different charge/discharge status. Based on the power control analysis, it is clear that the natural decoupled power flow management is one of the features of three-phase topology. So the 91 two control variables duty cycle and phase shift angle, can be controlled independently to realize MPPT and power flow between energy sources and load, respectively. 5.2 Future work Future research on the current-fed multiphase DAB DC–DC converter can be related to the DAB converter modeling, the DAB converter hardware optimization, new modulation strategy and new topology derived from multiphase DAB converter for new applications. The converter model presented in this work is just accurate in one operation area. When the operation area changes, new converter model should be calculated. One solution is that the harmonics model is used to replace this piecewise model, so that only one model can be applied in all operation areas. The hardware design can also be optimized further: the three-phase coupled inductor and one three-phase high frequency transformer can replace the single phase inductors and transformers to reduce power loss and improve power density. There are several control variables in current-fed DC-DC converter, which can provide flexible control strategy to implement some specific functions, such as minimum RSM current operation mode, zero reactive power mode or double frequency cancellation for PV or fuel cell applications. New modulation with duty cycle and phase shift angle combination is also useful to improve the system performance. New multiphase topology derived from multiphase DC-DC converter for high voltage, high power application. It is attractive for industry and academia to utilize Solid State Transformer (SST) to replace the conventional transformer for the features of instantaneous voltage regulation, fault isolation, power factor correction, etc. As the key component, DAB converter is a very good candidate for the bidirectional DC-DC converter. Multilevel multiphase DC-DC converter can be used in SST system. 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ECCE 2009. IEEE, pp.731-737, 20-24 Sept. 2009 [25] Zhao, C.; Round, S.D.; Kolar, J.W., "Full-order averaging modelling of zero-voltageswitching phase-shift bidirectional DC-DC converters," Power Electronics, IET , vol.3, no.3, pp.400-410, May 2010 102 [26] Krismer, F.; Kolar, J.W., "Accurate Small-Signal Model for the Digital Control of an Automotive Bidirectional Dual Active Bridge," Power Electronics, IEEE Transactions on, vol.24, no.12, pp.2756-2768, Dec. 2009 [27] “Valence U-charge RT data sheet”, www.valence.com 103 BIOGRAPHICAL SKETCH Zhan Wang was born in Hubei, China. He received his B.S. and M.S. degree in Electrical Engineering from Huazhong University of Science and Technology in 2002 and 2005, respectively. He is currently a Ph.D candidate in the ECE department at FAMU-FSU College of Engineering and also a Graduate Research Assistant with the Center for Advanced Power Systems (CAPS) at Florida State University (FSU). His research interests include energy storage elements, dc-dc converter, and renewable energy system. He has 9 publications listed below since 2007. [1] Zhan Wang; Hui Li, "A Soft Switching Three-phase Current-fed Bidirectional DC-DC Converter With High Efficiency Over a Wide Input Voltage Range," Power Electronics, IEEE Transactions on, vol.27, no.2, pp.669-684, Feb. 2012 [2] Lei Wang; Zhan Wang; Hui Li, "Asymmetrical Duty Cycle Control and Decoupled Power Flow Design of a Three-port Bidirectional DC-DC Converter for Fuel Cell Vehicle Application," Power Electronics, IEEE Transactions on , vol.27, no.2, pp.891-904, Feb. 2012 [3] Zhan Wang; Hui Li, " An Integrated Three-port Bidirectional DC-DC Converter for PVApplication on DC Distribution System," Power Electronics, IEEE Transactions on , Submitted. [4] Thomas Butschen; Zhan Wang; Murat Kaymak and Rik W. De Doncker, "Compact High Temperature Package with Smart Size-Optimized Gate Drive Unit for assembly of the DualICT," Accepted by IEEE Energy Conversion Congress and Expo (ECCE), 2012, Raleigh, NC, USA [5] Zhan Wang; Hui Li, "Integrated MPPT and bidirectional battery charger for PV application using one multiphase interleaved three-port dc-dc converter," Applied Power Electronics Conference and Exposition (APEC), 2011 Twenty-Sixth Annual IEEE , pp.295-300, 6-11 March 2011 [6] Zhan Wang; Hui Li, "Three-phase bidirectional DC-DC converter with enhanced current sharing capability," Energy Conversion Congress and Exposition (ECCE), 2010 IEEE , pp.1116-1122, 12-16 Sept. 2010 104 [7] Zhan Wang; Hui Li, "Unified modulation for three-phase current-fed bidirectional dc-dc converter under varied input voltage," Applied Power Electronics Conference and Exposition (APEC), 2010 Twenty-Fifth Annual IEEE , pp.807-812, 21-25 Feb. 2010 [8] Zhan Wang; Hui Li, "Optimized operating mode of current-fed dual half bridges dc-dc converters for energy storage applications," Energy Conversion Congress and Exposition, 2009. ECCE 2009. IEEE , pp.731-737, 20-24 Sept. 2009 [9] Lei Wang; Zhan Wang; Hui Li, "Optimized energy storage system design for a fuel cell vehicle using a novel phase shift and duty cycle control," Energy Conversion Congress and Exposition, 2009. ECCE 2009. IEEE , pp.1432-1438, 20-24 Sept. 2009 105