7. Introduction to DC/DC Converters Marc T. Thompson, Ph.D. Adjunct Associate Professor of Electrical Engineering Worcester Polytechnic Institute Thompson Consulting, Inc. 9 Jacob Gates Road Harvard, MA 01451 Phone: (978) 456-7722 Email: marctt@aol.com Website: http://members.aol.com/marctt/index.htm Portions of these notes excerpted from the CD ROM accompanying Mohan, Undeland and Robbins, Power Electronics Converters, Applications and Design, 3d edition, John Wiley 2003 Power Electronics Chapter 7 Introduction to DC/DC Converters 7-1 Summary • Non-isolated (i.e. no transformer) DC/DC converters Power Electronics Chapter 7 Introduction to DC/DC Converters 7-2 Block Diagram of Typical AC Input, Regulated DC Output System Power Electronics Chapter 7 Introduction to DC/DC Converters 7-3 Stepping Down a DC Voltage • In this example, the average value of the output voltage = DVin where D is the DUTY CYCLE in PWM (pulse-width modulation) control • D = ton/Ts Power Electronics Chapter 7 Introduction to DC/DC Converters 7-4 Step-Down (Buck) DC-DC Converter • Add LC filter to reduce switching ripple • Flyback diode also needed Power Electronics Chapter 7 Introduction to DC/DC Converters 7-5 Buck Converter: Waveforms • Steady state; inductor current flows continuously • Waveform below for buck in continuous conduction mode Power Electronics Chapter 7 Introduction to DC/DC Converters 7-6 Buck Converter: SPICE Circuit • Circuit shown: fsw = 200 kHz, D = 0.5 Power Electronics Chapter 7 Introduction to DC/DC Converters 7-7 Buck Converter: Startup Waveforms Power Electronics Chapter 7 Introduction to DC/DC Converters 7-8 Analysis for DC/DC Converter in Continuous Conduction and Steady State • In steady state, the inductor current returns to the same value every switching cycle, or every T seconds • Therefore, the inductor ripple current UP equals ripple DOWN • Several assumptions to simplify analysis: • Periodic steady state --- all startup transients have died out • Small ripple --- ripple is small compared to average values Power Electronics Chapter 7 Introduction to DC/DC Converters 7-9 Buck Converter in Continuous Conduction • In continuous conduction, buck converter has 2 states --switch OPEN and switch CLOSED iL D L Vcc Vo + R C vc - Switch closed (for time DT) iL Vcc iL L Vo + C L Vo + R vc vc - - di L VCC v o dt L Power Electronics Switch open (for time (1-D)T) di L vo dt L Chapter 7 Introduction to DC/DC Converters 7-10 Buck Converter in Continuous Conduction • The inductor ripple current UP equals ripple DOWN (VCC Vo ) DT Vo (1 D)T 0 L L Vo DVCC • We already knew this result from first principles, but this methodology of inductor Volt-second balance can be used to evaluate other more complicated DC/DC converters Power Electronics Chapter 7 Introduction to DC/DC Converters 7-11 Buck Converter: Waveforms at the Boundary of Cont./Discont. Conduction • ILB = critical current below which inductor current becomes discontinuous Power Electronics Chapter 7 Introduction to DC/DC Converters 7-12 Buck Converter: Discontinuous Conduction Mode • Steady state; inductor current discontinuous (i.e. it goes zero for a time) • Note that output voltage depends on load current Vo Vd D2 0.25 I o D2 I LB ,max Power Electronics Chapter 7 Introduction to DC/DC Converters 7-13 Buck: Limits of Discontinuous Conduction • The duty-ratio of 0.5 has the highest value of the critical current • For low output current, buck goes discontinuous Power Electronics Chapter 7 Introduction to DC/DC Converters 7-14 Buck: Limits of Cont./Discont. Conduction • In regulated power supply, Vd may fluctuate but Vo is kept constant by control of D Power Electronics Chapter 7 Introduction to DC/DC Converters 7-15 Buck Conv.: Output Voltage Ripple • ESR is assumed to be zero; continuous conduction mode Power Electronics Chapter 7 Introduction to DC/DC Converters 7-16 Buck Conv.: Output Voltage Ripple • ESR is assumed to be zero iL , pp Vo (1 D )T Vo (1 D ) L f sw L 1 T iL, pp Vo (1 D) Q 8 f sw2 L 2 2 2 vo , pp Q Vo (1 D ) C 8 f sw2 LC Power Electronics Chapter 7 Introduction to DC/DC Converters 7-17 Buck Conv.: Calculations • Shown for SPICE example with fsw = 200 kHz, D = 0.5, L = 33 µH, C = 10 µF, Io = 1A iL, pp vo , pp Vo (1 D ) (5)(1 0.5) 0.38 A 5 6 f sw L ( 2 10 )( 33 10 ) Q Vo (1 D ) (5)(1 0.5) 24 mV 2 5 2 6 6 C 8 f sw LC 8( 2 10 ) (33 10 )(10 10 ) Power Electronics Chapter 7 Introduction to DC/DC Converters 7-18 Buck: SPICE Result in Periodic Steady State • Analysis shows inductor ripple = 0.38 A-pp, output voltage ripple = 24 mV-pp, confirmed by SPICE Power Electronics Chapter 7 Introduction to DC/DC Converters 7-19 Pulse-Width Modulation (PWM) in DC-DC Converters vcontrol D Vˆst Power Electronics Chapter 7 Introduction to DC/DC Converters 7-20 Step-Up (Boost) DC-DC Converter • Output voltage must be greater than the input Power Electronics Chapter 7 Introduction to DC/DC Converters 7-21 Boost Converter Waveforms • Continuous current conduction mode Switch closed: di L VCC dt L Switch open: di L VCC v o dt L Inductor Volt-second balance: VCC DT (VCC Vo )(1 D)T 0 L L V Vo CC 1 D Power Electronics Chapter 7 Introduction to DC/DC Converters 7-22 Boost: Limits of Cont./Discont. Conduction • The output voltage is held constant • For low load current, current conduction becomes discontinuous Power Electronics Chapter 7 Introduction to DC/DC Converters 7-23 Boost Converter: Discont. Conduction • Occurs at light loads Power Electronics Chapter 7 Introduction to DC/DC Converters 7-24 Boost: Limits of Cont./Discont. Conduction • The output voltage is held constant Power Electronics Chapter 7 Introduction to DC/DC Converters 7-25 Boost Converter: Effect of Parasitics • The duty-ratio D is generally limited before the parasitic effects become significant Power Electronics Chapter 7 Introduction to DC/DC Converters 7-26 Boost Converter Output Ripple • ESR is assumed to be zero • Assume that all the ripple component of diode current flows through capacitor; DC component flows through resistor Power Electronics Chapter 7 Introduction to DC/DC Converters 7-27 Step-Down/Up (Buck-Boost) Converter • The output voltage can be higher or lower than the input voltage • Note output phase inversion Power Electronics Chapter 7 Introduction to DC/DC Converters 7-28 Buck-Boost Converter: Waveforms • Continuation conduction mode Switch closed: di L VCC dt L Switch open: di L v o dt L Inductor Volt-second balance: VCC DT Vo (1 D)T 0 L L DVCC Vo 1 D Power Electronics Chapter 7 Introduction to DC/DC Converters 7-29 Buck-Boost: Limits of Cont./Discont. Conduction • The output voltage is held constant Power Electronics Chapter 7 Introduction to DC/DC Converters 7-30 Buck-Boost: Discontinuous Conduction • This occurs at light loads Power Electronics Chapter 7 Introduction to DC/DC Converters 7-31 Buck-Boost Converter: Limits of Cont./Discont. Conduction • The output voltage is held constant Power Electronics Chapter 7 Introduction to DC/DC Converters 7-32 Buck-Boost Converter: Effect of Parasitics • The duty-ratio is limited to avoid these parasitic effects from becoming significant Power Electronics Chapter 7 Introduction to DC/DC Converters 7-33 Buck-boost Converter: Output Voltage Ripple • ESR is assumed to be zero Power Electronics Chapter 7 Introduction to DC/DC Converters 7-34 Cuk DC-DC Converter • The output voltage can be higher or lower than the input voltage • Capacitor C1 is primary means of storing and transferring energy from input to output • When switch is ON, C1 discharges through the switch and transfers energy to the output • When switch is OFF, capacitor C1 is charged through the diode by energy from the input and L1 Power Electronics Chapter 7 Introduction to DC/DC Converters 7-35 Cuk DC-DC Converter: Waveforms • The capacitor voltage is assumed constant (very large) • Note phase inversion at the output Vo D Vd 1 D Power Electronics Chapter 7 Introduction to DC/DC Converters 7-36 SEPIC Converter • Single-ended primary inductance converter (SEPIC) • Can buck or boost the voltage • Note that output is similar to buck-boost, but without a phase inversion Vo D Vd 1 D Power Electronics Chapter 7 Introduction to DC/DC Converters 7-37 Converter for DC-Motor Drives • Four quadrant operation is possible • For: • DC motor drives • DC to AC inverters for UPS Power Electronics Chapter 7 Introduction to DC/DC Converters 7-38 Converter Waveforms • Bi-polar voltage switching Power Electronics Chapter 7 Introduction to DC/DC Converters 7-39 Converter Waveforms • Uni-polar voltage switching Power Electronics Chapter 7 Introduction to DC/DC Converters 7-40 Output Ripple in Converters for DC-Motor Drives • Bi-polar and uni-polar voltage switching Power Electronics Chapter 7 Introduction to DC/DC Converters 7-41 Switch Utilization in DC-DC Converters • It varies significantly in various converters • PT = VTIT where VT and IT are peak switch voltage and current • In direct converters (buck and boost) switch utilization is good; in indirect converter (buck-boost and Cuk) switch utilization is poor Power Electronics Chapter 7 Introduction to DC/DC Converters 7-42 Equivalent Circuits in DC-DC Converters • Replacing inductors and capacitors by current and voltage sources, respectively Power Electronics Chapter 7 Introduction to DC/DC Converters 7-43 Reversing the Power Flow in DC-DC Conv. • For power flow from right to left, the input current direction should also reverse Power Electronics Chapter 7 Introduction to DC/DC Converters 7-44 Real-World Issue: Capacitor ESR • Real-world capacitors have equivalent series resistance (ESR) • This ESR may have dominant effect on output ripple Power Electronics Chapter 7 Introduction to DC/DC Converters 7-45 Effects of Capacitor ESR • Without ESR, output ripple is 24 mV-pp • ESR has increased ripple to approximately 30 mV-pp Power Electronics Chapter 7 Introduction to DC/DC Converters 7-46