Design, modeling and characterization of a microinductor for future DC-DC power converters

Experimental, analytical and simulated data are presented in this article to assess the performance of electrodeposited nickel-iron within a novel solenoid microinductor. A design flowchart highlights the primary design principles when developing a microscale magnetic component for DC-DC power converters. Thermal modeling is used to predict the operational conditions that generate undesirable thermal generation within the component. Operating at 0.5MHz, the microinductor achieves an efficiency and power density of 78% and 7.8 W/cm3, respectively.

DC-DC Power Converters Featuring Wide-Bandgap Devices

This work focuses on the design of high-efficient DC-DC converters based on WBG power devices. The first objective is the development of an isolated bidirectional converter for the distribution network of future electrical aircrafts. A SiC-based Dual Active Bridge converter is designed and fabricated. Control strategies for individual and parallel operations are investigated and implemented into a FPGA platform. Experimental results on 1.2kW 270V/28V prototype are presented to confirm the proper behavior of the proposed solution. The second project belongs to the field of photovoltaic systems and aims to develop a three-port converter with multiple power elements interfacing capability. A GaN-based Triple Active Bridge has been designed, regarding both the controller and the hardware realization.

Improved Direct Power Control of Grid Connected DC/AC Converters

This paper proposes new direct power control (DPC) strategies for three-phase DC/AC converters with improved dynamic response and steady-state performance. As with an electrical machine, source and converter flux which equal the integration of the respective source and converter voltage are used to define active and reactive power flow. Optimization of the look-up-table used in conventional DPC is outlined first, to improve the power control and reduce the current distortion. Then constant switching frequency DPC is developed where the required converter voltage vector within a fixed half switching period is calculated directly from the active and reactive power errors. Detailed angle compensation due to the finite sampling frequency and the use of integral controller to further improve the power control accuracy, are described. Both simulation and experimental results are used to compare conventional DPC and vector control, and to demonstrate the effectiveness and robustness of the proposed control strategies during active and reactive power steps, and line inductance variations.

Novel communication method between power converters for DC micro-grid applications

Communication between power converters is vital for high performance DC micro-grids controls. However, for residential DC micro-grid applications, using external communication link would increase the system cost, and reduce the system flexibility and reliability. This paper presents a novel method to enable the conventional DC/DC converters to transmit data via the common DC Bus. With this technology, cost-effective low bandwidth communication links between power converters can be established within a DC micro-grid, and advanced distributed control algorithms can be developed. A reliable communication with 2 kbps transmission rate has been implemented between the Boost converters through the common input DC bus.

DC power line communication based on power/signal dual modulation in phase shift full bridge converters

For intelligent DC distributed power systems, data communication plays a vital role in system control and device monitoring. To achieve communication in a cost effective way, power/signal dual modulation (PSDM), a method that integrates data transmission with power conversion, can be utilized. In this paper, an improved PSDM method using phase shift full bridge (PSFB) converter is proposed. This method introduces a phase control based freedom in the conventional PSFB control loop to realize communication using the same power conversion circuit. In this way, decoupled data modulation and power conversion are realized without extra wiring and coupling units, and thus the system structure is simplified. More importantly, the signal intensity can be regulated by the proposed perturbation depth, and so this method can adapt to different operating conditions. Application of the proposed method to a DC distributed power system composed of several PSFB converters is discussed. A 2kW prototype system with an embedded 5kbps communication link has been implemented, and the effectiveness of the method is verified by experimental results.

Assessment of microInductors for DC-DC converters

There are increasing demands on the power density and efficiency of DC-DC power converters due to the soaring functionality and operational longevity required for today's electronic products. In addition, DC-DC converters are required to operate at new elevated frequencies in the MHz frequency regime. Typical ferrite cores, whose useable flux density falls drastically at these frequencies, have to be replaced and a method of producing compact component windings developed. In this study, two types of microinductors, pot-core and solenoid, for DC-DC converter applications have been analyzed for their performance in the MHz frequency range. The inductors were manufactured using an adapted UV-LIGA process and included electrodeposited nickel-iron and the commercial alloy Vitrovac 6025 as core materials. Using a vibrating sample magnetometer (VSM) and a Hewlett Packard 4192A LF- impedance analyzer, the inductor characteristics such as power density, efficiency, inductance and Q-factor were recorded. Experimental, finite element and analytical results were used to assess the suitability of the magnetic materials and component geometries for low MHz operation.

Variable-Structure Control Design of Switched Systems With an Application to a DC-DC Power Converter

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

A new generation of high voltage pulsed power converters

Improving efficiency and flexibility in pulsed power supply technologies are the most substantial concerns of pulsed power systems specifically for plasma generation. Recently, the improvement of pulsed power supply becomes of greater concern due to extension of pulsed power applications to environmental and industrial areas. A current source based topology is proposed in this paper which gives the possibility of power flow control. The main contribution in this configuration is utilization of low-medium voltage semiconductor switches for high voltage generation. A number of switch-diode-capacitor units are designated at the output of topology to exchange the current source energy into voltage form and generate a pulsed power with sufficient voltage magnitude and stress. Simulations have been carried out in Matlab/SIMULINK platform to verify the capability of this topology in performing desired duties. Being efficient and flexible are the main advantages of this topology.

High efficiency auxiliary power converters

The auxiliary load DC-DC converters of the Sunshark solar car have never been examined. An analysis of the current design reveals it is complicated, and inefficient. Some simple measures to greatly improve the efficiency are present which will achieve an overall worthwhile power saving. Two switch-mode power supply DC-DC converter designs are presented. One is a constant current supply for the LED brake and turn indicators, which allows them to be powered directly from the main DC bus, and switched only as necessary. The second is a low power flyback converter, which employs synchronous rectification among other techniques to achieve good efficiency and regulation over a large range of output powers. Practical results from both converters, and an indication of the overall improvement in system efficiency will be offered.

High voltage DC power supply topology for pulsed load applications with converter switching synchronized to load pulses

High voltage power supplies for radar applications are investigated, which are subjected to pulsed load (125 kHz and 10% duty cycle) with stringent specifications (<0.01% regulation, efficiency>85%, droop<0.5 V/micro-sec.). As good regulation and stable operation requires the converter to be switched at much higher frequency than the pulse load frequency, transformer poses serious problems of insulation failure and higher losses. This paper proposes a methodology to tackle the problems associated with this type of application. Synchronization of converter switching with load pulses enables the converter to switch at half the load switching frequency. Low switching frequency helps in ensuring safety of HV transformer insulation and reduction of losses due to skin and proximity effect. Phase-modulated series resonant converter with ZVS is used as the power converter.

Input voltage modulated high voltage DC power supply topology for pulsed load applications

High voltage power supplies for radar applications are investigated which are subjected to pulsed load with stringent specifications. In the proposed solution, power conversion is done in two stages. A low power-high frequency converter modulates the input voltage of a high power-low frequency converter. This method satisfies all the performance specifications and takes care of the critical aspects of HV transformer.

Beat frequency oscillations in the output voltage of high voltage DC power supplies under pulsed loading

High voltage power supplies for radar applications are investigated, which are subjected to pulsed load (125 kHz and 10% duty cycle) with stringent specifications (<0.01% regulation, efficiency>85%, droop<0.5 V/micro-sec.). As good regulation and stable operation requires the converter to be switched at much higher frequency than the pulse load frequency, transformer poses serious problems of insulation failure and higher losses. Few converter topologies are proposed to tackle these problems. A study is made regarding the beat frequency oscillations that may exist with pulsed loading. It is illustrated with respect to the proposed converter topologies. Methods are proposed to eliminate or minimize these oscillations.

Implementation of a DC-DC converter with variable structure control of switched systems

This paper presents a control method for a class of continuous-time switched systems, using state feedback variable structure controllers. The method is applied to the control of a two-cell dc-dc buck converter and a control circuit design using the software PSpice is proposed. The design is based on Lyapunov-Metzler-SPR systems and the performance of the resulting control system is superior to that afforded by a recently-proposed alternative sliding-mode control technique. The dc-dc power converters are very used in industrial applications, for instance, in power systems of hybrid electric vehicles and aircrafts. Good results were obtained and the proposed design is also inexpensive because it uses electric components that can be easily found for the hardware implementation. Future researches on the subject include the hardware validation of the dc-dc converter controller and the robust control design of switched systems, with structural failures. © 2011 IEEE.

Development and verification of control and protection strategies in hybrid AC/DC power systems for smart grid applications

Modern power networks incorporate communications and information technology infrastructure into the electrical power system to create a smart grid in terms of control and operation. The smart grid enables real-time communication and control between consumers and utility companies allowing suppliers to optimize energy usage based on price preference and system technical issues. The smart grid design aims to provide overall power system monitoring, create protection and control strategies to maintain system performance, stability and security. This dissertation contributed to the development of a unique and novel smart grid test-bed laboratory with integrated monitoring, protection and control systems. This test-bed was used as a platform to test the smart grid operational ideas developed here. The implementation of this system in the real-time software creates an environment for studying, implementing and verifying novel control and protection schemes developed in this dissertation. Phasor measurement techniques were developed using the available Data Acquisition (DAQ) devices in order to monitor all points in the power system in real time. This provides a practical view of system parameter changes, system abnormal conditions and its stability and security information system. These developments provide valuable measurements for technical power system operators in the energy control centers. Phasor Measurement technology is an excellent solution for improving system planning, operation and energy trading in addition to enabling advanced applications in Wide Area Monitoring, Protection and Control (WAMPAC). Moreover, a virtual protection system was developed and implemented in the smart grid laboratory with integrated functionality for wide area applications. Experiments and procedures were developed in the system in order to detect the system abnormal conditions and apply proper remedies to heal the system. A design for DC microgrid was developed to integrate it to the AC system with appropriate control capability. This system represents realistic hybrid AC/DC microgrids connectivity to the AC side to study the use of such architecture in system operation to help remedy system abnormal conditions. In addition, this dissertation explored the challenges and feasibility of the implementation of real-time system analysis features in order to monitor the system security and stability measures. These indices are measured experimentally during the operation of the developed hybrid AC/DC microgrids. Furthermore, a real-time optimal power flow system was implemented to optimally manage the power sharing between AC generators and DC side resources. A study relating to real-time energy management algorithm in hybrid microgrids was performed to evaluate the effects of using energy storage resources and their use in mitigating heavy load impacts on system stability and operational security.