Modified double dual boost structure with common ground and low side gate driving for dc dc converter and pfc rectifier

Thesis for the Degree of Ph.D Modified Double-Dual-Boost Structure with Common Ground and Low-Side Gate Driving for DC-DC Converter and PFC Rectifier School of Architectural, Civil, Environmental, and Energy Engineering, Major in Energy Engineering The Graduate School Nguyen Chan Viet June 2022 The Graduate School Kyungpook National University Modified Double-Dual-Boost Structure with Common Ground and Low-Side Gate Driving for DC-DC Converter and PFC Rectifier Nguyen Chan Viet 2022 Modified Double-Dual-Boost Structure with Common Ground and Low-Side Gate Driving for DC-DC Converter and PFC Rectifier Nguyen Chan Viet School of Architectural, Civil, Environmental, and Energy Engineering, Major in Energy Engineering The Graduate School Supervised by Professor Honnyong Cha Approved as a qualified thesis of Nguyen Chan Viet for the degree of Ph.D by the Evaluation Committee June 2022 Chairman Prof Bon-Gwan Gu 인 ○ Prof Honnyong Cha 인 ○ Prof Byungcho Choi 인 ○ Prof Byeongcheol Han 인 ○ Prof Jae-Jung Jung 인 ○ The Graduate School Council Kyungpook National University Modified Double-Dual-Boost Structure with Common Ground and Low-Side Gate Driving for DC-DC Converter and PFC Rectifier Viet Chan Nguyen School of Architectural, Civil, Environmental, and Energy Engineering, Major in Energy Engineering The Graduate School, Kyungpook National University Daegu, Korea (Supervised by Professor Honnyong Cha) (Abstract) This thesis proposes a modified double-dual-boost (MDDB) highconversion-ratio DC-DC converter The proposed converter is derived from the existing double-dual-boost (DDB) converter by a simple yet effective circuit modification The new structure inherits all the advantages of the existing DDB converter as high voltage gain, low voltage stress on switching devices, and power-sharing function Moreover, due to the circuit modification, the input and output can share a common ground, enabling the use of low-side gate drivers for all switching devices When compared with the existing DDB converter, the proposed converter requires only one more capacitor and one more inductor However, the seemingly two inductors can be integrated into a single inductor Thus, the overall magnetic volume is the same as the conventional DDB converter i Unlike the DDB converter, the proposed structure can be used for power-factor-correction (PFC) applications The boost or interleaved boost converter in the conventional PFC structure can be replaced by the proposed converter to reduce the cost and improve the efficiency Owing to the intrinsic power-sharing between the phases, the number of current sensors is reduced It results in reducing the hardware cost and the complexity of the controller Moreover, the MDDB converter has a higher voltage gain but lower switching devices voltage stress than the conventional two-phase interleaved boost converter (2P-IBC); therefore, the proposed PFC can achieve higher efficiency, especially at low-line voltage The above advantages make the proposed structure quite suitable for universal-line (85–265 VRMS) PFC applications The first Chapter of this thesis is devoted to the introduction of DC-DC boost converters and the existing DDB converter The MDDB converter is introduced and is carefully analyzed in the second Chapter After that, the PFC based on the MDDB structure is presented in the third Chapter, and the conclusions are given in the final Chapter ii Acknowledgments I would like to express my most sincere gratitude and appreciation to my supervisor, Prof Honnyong Cha, for his constant support, motivation, encouragement, and guidance throughout my studies at Kyungpook National University His amazing knowledge, advice, and expertise have been a valuable source for my Ph D research work I would like to thank Prof Honnyong Cha for allowing me to grow as a research scientist I would like to thank my Ph.D dissertation committee members Prof Bon-Gwan Gu, Prof Byungcho Choi, Prof Byeongcheol Han, Prof Jae-Jung Jung, and Prof Honnyong Cha for serving as my Ph.D dissertation committee members I also want to thank them for their valuable comments and suggestions Further, I would like to thank my colleagues at Power Electronics and Magnetics Design Laboratory (PEMD), Dr Kisu Kim, Dr Fazal Akbar, Dr Tien-The Nguyen, Mr Bang Le-Huy Nguyen, Mr Dai-Van Bui, Mr Nabeel Naseem, Mr Emmanuel Seun Oluwasogo, Mr Ubaid Ahmad, Mr Faramarz Faraji Mr Jeonghun Kim, Mr Seunghoon Lee, Mr Daheon Hong, Mr Jaeseong Lim, Mr Yeongjin Kim, Mr Dongheon Lee, Mr Juyoung Park for letting my Ph.D studies and research enjoyable and memorable With my heartfelt respect, I would like to thank my parents, my sister, and my girl for their everlasting love and support Without them, my Ph.D would have never been possible iii List of Content Chapter I Introduction 1.1 Categorization of Step-Up DC-DC Converters 1.1.1 Isolated and non-isolated DC-DC converters 1.1.2 Unidirectional and bidirectional DC-DC converters 1.1.3 Voltage-fed and current-fed DC-DC Converters 1.1.4 Hard-switched and soft-switched DC-DC converters 1.1.5 The requirements of a DC-DC converter for PFC applications 1.2 Voltage-Boosting Techniques 1.2.1 Switched capacitor (charge pump) 1.2.2 Switched inductor and voltage lift 1.2.3 Magnetic coupling 11 1.2.4 Voltage multiplier cells 12 1.3 Double-Dual-Boost Converter 14 1.3.1 Interleaved double-dual boost converter 14 1.3.2 Operation principle 15 Chapter II Modified Double-Dual-Boost Structure 20 2.1 The Motivation of Circuit Modifications 20 2.2 Topology Derivation 21 2.3 Operation Principle of the Proposed DDB Converter 24 2.4 Characteristics of the MDDB Converter 29 2.4.1 Voltage gain 29 2.4.2 Inductor current balancing 32 iv 2.4.3 Comparison of the 2P-IBC, the existing/proposed DDB converters 34 2.4.4 Coupled inductor L2, L3 36 2.4.5 Input current ripple 40 2.4.6 Semiconductor losses analysis 44 2.5 Simulation and Experimental Results 50 2.5.1 Simulation result 50 2.5.2 Experiment result 54 2.6 Influences of Leakage Inductance on the MDDB Converter 59 2.7 Influences of turns-ratio on the proposed DDB converter 62 Chapter III Power Factor Correction Based on the MDDB Structure 67 3.1 Overview of Power Factor Correction 67 3.2 Design Guideline 74 3.2.1 Inductor L1, L2, and L3 74 3.2.2 Capacitors C1 and C2 76 3.2.3 Output capacitor Co 76 3.2.4 Switching devices S1, S2, D1, and D2 77 3.3 PFC Controller 78 3.3.1 Current loop 79 3.3.2 Voltage loop: 80 3.3.3 Voltage feed-forward compensator 80 3.3.4 Start-up sequence 82 3.4 Simulation and Experimental Result 85 3.4.1 The simulation results 85 3.4.2 Experimental results 92 v Chapter IV Contribution 4.1 101 Summary and Contribution 101 4.1.1 Summary 101 4.1.2 Publication 104 References 105 vi List of figures Chapter I Fig 1.1 Categorization of step-up DC-DC converters Fig 1.3 Two voltage-doublers are cascade connected Fig 1.2 The operation stages of the voltage-doubler based on the switched capacitor technique a) Stage 1: C is charged b) Stage 2: C discharges in series with Vin Fig 1.4 The operation of boost converter with switched inductor cell a) Stage (S is turned-on) b) Stage (S is turned-off) Fig 1.5 The operation of: a) Basic switched inductor cell b) Self-lift switched inductor cell c) Double self-lift switched inductor cell 10 Fig 1.6 Active switched inductor converter based on switched inductor 11 Fig 1.7 Classic voltage multiplier cells a) Switched/diode capacitor VMC b) VMC with capacitor, diode, and inductor c) VMC with resonant inductor 13 Fig 1.8 Boost converter based on Voltage multiplier circuits 13 Fig 1.9 Double-dual-boost converter 14 Fig 1.10 Operation of the DDB converter (a) Mode (b) Mode (c) Mode (d) Mode 16 Fig 1.11 Key waveforms of the DDB converter when D < 0.5 17 Fig 1.12 Key waveforms of the DDB converter when D > 0.5 18 Chapter II Fig 2.1 Double-dual-boost converter 20 Fig 2.2 Derivation of the proposed converter (a) Step 1: move (L2) to the top and add L3 and Co (b) Step 2: connect C2 to the top (c) Step 3: move D2 to the top 23 Fig 2.3 Modified double-dual-boost converter 24 Fig 2.4 Re-drawing of the modified double-dual-boost converter 24 vii CHAPTER IV CONTRIBUTION 4.1 Summary and Contribution 4.1.1 Summary This thesis proposed the MDDB converter for DC-DC and PFC applications The following points are the features of the proposed converter As shown in TABLE 4.1, the proposed converter has the same high voltage gain and low voltage stresses on semiconductor devices as well as retains the same interleaving and power-sharing function as the existing DDB converter Moreover, the proposed converter has some additional features that cannot be obtained in the existing DDB converter First, the proposed converter shares a common ground between the converter input and output Therefore, no isolated sensor is required for feedback control Second, all switches of the proposed converter can be operated with the low-side gate driver The aforementioned advantages significantly reduce the cost, size, and complexity of the converter Regarding the PFC applications, TABLE 4.2 shows the comparison between 2PIBC PFC and MDDB PFC, the proposed PFC requires only one current sensor instead of two, and the inductance requirement is also lower Therefore, reducing the hardware 101 cost and the complexity of the PFC controller can be achieved In addition, the low-line efficiency of the proposed PFC is improved, making it more suitable for the universal line input PFC applications TABLE 4.1 THE COMPARISON AMONG 2P-IBC, MDDB CONVERTER, AND DDB CONVERTER Converter 2P-IBC MDDB converter DDB converter Voltage gain 1−𝐷 1+𝐷 1−𝐷 1+𝐷 1−𝐷 Power-sharing function No Yes Yes Common ground Yes Yes No Low-side gate driving Yes Yes No Voltage stress on switching devices Vo 1−𝐷 𝑉 1+𝐷 𝑜 1−𝐷 𝑉 1+𝐷 𝑜 Input current ripple High Low Low Number of components compared to 2P-IBC - more capacitor more capacitor 102 TABLE 4.2 THE COMPARISON BETWEEN 2P-IBC PFC and MDDB PFC Converter 2P-IBC PFC MDDB PFC Power-sharing function No Yes Efficiency at the low-line input voltage Low High Input current ripple High Low Common mode noise Low Low PFC controller current loops and voltage loop current loop and voltage loop Number of sensors current sensors and voltage sensors current sensor and voltage sensors Number of components compared to 2P-IBC PFC - more small capacitor 103 4.1.2 Publication [1] V -C Nguyen, H Cha, D -V Bui and B Choi, "Modified Double-Dual-Boost High-Conversion-Ratio DC–DC Converter With Common Ground and LowSide Gate Driving," IEEE Trans Power Electron, vol 37, no 5, pp 4952-4956, May 2022 [2] V -C Nguyen, H Cha, D -V Bui and B Choi, "Asymmetrical PWM Scheme to Widen the Operating Range of the Three-Phase Series-Capacitor Buck Converter," IEEE Journal of Emerging and Selected Topics in Power Electronics, (early accept) [3] D -V Bui, H Cha and V -C Nguyen, "Asymmetrical PWM Series-Capacitor High-Conversion-Ratio DC–DC Converter," IEEE Trans Power Electron, vol 36, no 8, pp 8628-8633, 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제안한다 제안하는 컨버터는 기존의 double-dual-boost (DDB) 컨버터의 간단하고 효과적인 회로 수정을 통해 파생되었다 이 새로운 구조는 여전히 높은 전압 이득, 스위칭 소자의 낮은 전압 스트레스, 전력 공유 등 기존 DDB 컨버터의 장점을 모두 가지고 있다 또한 간단한 회로의 개선을 통해 입력과 출력이 같은 접지를 공유해 모든 스위치에 비절연 게이트 구동이 가능하다 기존의 DDB 컨버터와 비교했을 시 제안하는 컨버터는 하나의 커패시터와 인덕터가 추가로 필요하지만 두 인덕터는 하나의 결합 인덕터로 결합이 가능하기에 전체 회로의 자기 부피는 기존의 DDB 컨버터와 동일하다 114 기존의 DDB 컨버터와 달리, 제안하는 구조는 역률 개선 회로 (power-factorcorrection, PFC)에 적용이 가능하다 제안하는 MDDB 구조는 기존 PFC 구조의 부스트 컨버터 혹은 인터리브드 부스트 컨버터를 대체할 수 있으며 낮은 비용과 높은 효율을 나타낸다는 장점을 가진다 또한 각 상 간의 전력 공유 특성을 통해 전류 센서를 절반으로 줄일 수 있어 비용과 제어기의 복잡성을 감소시킨다 추가적으로 MDDB 컨버터는 기존의 상 인터리브드 부스트 컨버터(2P-IBC)와 비교했을 시 높은 전압 이득과 낮은 전압 스트레스의 장점을 가지고 있으며 따라서 제안하는 PFC 는 특히 낮은 입력 전압에서 높은 효율을 달성할 수 있다 이러한 장점들을 통해 제안하는 회로는 넓은 입력 전압 범위 (85-265 Vrms)의 PFC 회로에 적용이 가능하다 본 논문의 첫번째 장은 DC-DC 부스트 컨버터와 기존 DDB 컨버터에 대해 소개한다 제안하는 MDDB 컨버터는 두번째 장에서 상세하게 분석하며 MDDB 구조 기반의 PFC 는 세번째 장에서 소개한다 최종적으로 마지막 장에서 본 논문의 결론을 제시한다 115