In this paper, a detailed design procedure is presented for a bidirectional CLLLC-type resonant converter for a battery charging application. This converter is similar to an LLC-type resonant converter with an extra inductor and capacitor in the secondary side. Soft-switching can be ensured in all switches without additional snubber or clamp circuitry. Because of soft-switching in all switches, very high-frequency operation is possible; thus, the size of the magnetics and the filter capacitors can be made small. To reduce the size and cost of the converter, a CLLC-type resonant network is derived from the original CLLLC-type resonant network. First, in this paper, an equivalent model for the bidirectional converter is derived for the steady-state analysis. Then, the design methodology is presented for the CLLLC-type resonant converter. Design of this converter includes determining the transformer turns ratio, design of the magnetizing inductance based on ZVS condition, design of the resonant inductances and capacitances. Then, the CLLC-type resonant network is derived from the CLLLC-type resonant network. To validate the design procedure, a 3.5-kW converter was designed following the guidelines in the proposed methodology. A prototype was built and tested in the laboratory. Experimental results verified the design procedure presented.

Design of Bidirectional DC–DC Resonant Converter for Vehicle-to-Grid (V2G) Applications

This paper presents a novel ZVZCS full-bridge DC/DC converter, which is able to process and deliver power efficiently over very wide load variations. The proposed DC/DC converter is part of a plug-in AC/DC converter used to charge the traction battery (high voltage battery) in an electric vehicle. The key challenge in this application is operation of the full-bridge converter from absolutely no-load to full-load conditions. In order to confirm reliable operation of the full-bridge converter under such wide load variations, the converter should not only operate with soft-switching from full load to no-load condition with satisfactory efficiency for the full range of operation, but also the voltage across the output diode bridge needs to be clamped to avoid any adverse voltage overshoots arising during turn-OFF of the output diodes as commonly found in regular full bridge converters. In order to achieve such stringent requirements and high reliability, the converter employs a symmetric passive near lossless auxiliary circuit to provide the reactive current for the full-bridge semiconductor switches, which guarantees zero voltage switching at turn-ON times for all load conditions. Moreover the proposed topology is based on a current driven rectifier in order to clamp the voltage of the output diode bridge and also satisfy ZVZCS operation of the converter resulting in superior efficiency for all load conditions. In this paper operation of the converter is presented in detail followed by analytical design procedure. Experimental results provided from a 3KW prototype validate the feasibility and superior performance of the proposed converter.

A Novel ZVZCS Full-Bridge DC/DC Converter Used for Electric Vehicles

The interleaving technique is necessary for LLC resonant converters to achieve high power level. The advantages include expanded power capacity, lower output ripple current, and higher light-load efficiency by using phase shedding. However, conventional frequency-controlled LLC converters will lose regulation in individual phases if all the phases are operating at the same switching frequency, causing load sharing problem. Existing load sharing solutions for interleaved LLC converters all have limitations. In this paper, a switch-controlled capacitor (SCC) modulated LLC converter (SCC-LLC) is presented to solve the load-sharing problem. With constant switching frequency, interleaving and phase shedding can be achieved. A 600-W, two-phase interleaved constant frequency SCC-LLC prototype is built to verify the feasibility and demonstrate the advantages.

An Interleaved LLC Resonant Converter Operating at Constant Switching Frequency

Modular photovoltaic (PV) power conditioning systems (PCSs) require a high-efficiency dc-dc converter stage capable of regulation over a wide input voltage range for maximum power point tracking. In order to mitigate ground leakage currents and to be able to use a high-efficiency, nonisolated grid-tied inverter, it is also desirable for this microconverter to provide galvanic isolation between the PV module and the inverter. This paper presents a novel, isolated topology that is able to meet the high efficiency over a wide input voltage range requirement. This topology yields high efficiency through low circulating currents, zero-voltage switching (ZVS) and low-current switching of the primary side devices, ZCS of the output diodes, and direct power transfer to the load for the majority of switching cycle. This topology is also able to provide voltage regulation through basic fixed-frequency pulsewidth modulated (PWM) control. These features are able to be achieved with the simple addition of a secondary-side bidirectional ac switch to the isolated series resonant converter. Detailed analysis of the operation of this converter is discussed along with a detailed design procedure. Experimental results of a 300-W prototype are given. The prototype reached a peak power stage efficiency of 98.3% and a California Energy Commission (CEC) weighted power stage efficiency of 98.0% at the nominal input voltage.

A Bidirectional-Switch-Based Wide-Input Range High-Efficiency Isolated Resonant Converter for Photovoltaic Applications

This paper first presents a hybrid-switching step-down dc-dc converter, and then, by introducing transformer isolation, a novel hybrid-switching phase-shift full-bridge dc-dc converter is derived for electric vehicle battery chargers. The proposed converter provides wide zero-voltage-switching range in the leading-leg switches, achieves zero-current-switching for lagging-leg switches, and uses a hybrid-switching method to avoid freewheeling circulating losses in the primary side. Because the resonant capacitor voltage of the hybrid-switching circuit is applied between the bridge rectifier and the output inductor for the duration of the freewheeling intervals, a smaller sized output inductor can be utilized. With the current rectifier diode of the hybrid-switching circuit providing a clamping path, the voltage overshoots that arise during the turn-off of the rectifier diodes are eliminated and the voltage stress of bridge rectifier is clamped to the minimal achievable value, which is equal to secondary-reflected input voltage of the transformer. The inductive energy stored in the output inductor and the capacitive energy stored in the resonant capacitor of the hybrid-switching circuit are transferred to the output simultaneously during the freewheeling intervals with only one diode in series in the current path, achieving more effective and efficient energy transfer. The effectiveness of the proposed converter was experimentally verified using a 3.6-kW prototype circuit designed for electric vehicle onboard chargers. Experimental results of the hardware prototype show that the converter achieves a peak efficiency of 98.1% and high system efficiencies over wide output voltage and power ranges.

Hybrid-Switching Full-Bridge DC–DC Converter With Minimal Voltage Stress of Bridge Rectifier, Reduced Circulating Losses, and Filter Requirement for Electric Vehicle Battery Chargers

The conventional high-frequency phase-shifted zero-voltage-switching (ZVS) full-bridge DC/DC converter has a disadvantage, in that a circulating current flows through transformer and switching devices during the freewheeling interval. Due to this circulating current, RMS current stress, conduction losses of the transformer and switching devices are increased. To alleviate this problem, this paper proposes an improved zero-voltage zero-current switching (ZVZCS) phase-shifted full-bridge (FB) DC/DC converter with a modified energy-recovery snubber (ERS) attached at the secondary side of transformer. Also, the small signal model of the proposed ZVZCS FB DC/DC converter is derived by incorporating the effects introduced by a transformer leakage inductance and an ERS to achieve ZVZCS. Both analysis and experiment are performed to verify the proposed topology by implementing a 7-kW (120 VDC, 58 A) 30-kHz insulated-gate-bipolar-transistor-based experimental circuit.

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A ZVZCS PWM FB DC/DC converter using a modified energy-recovery snubber

Nowadays, some applications require high efficiency under wide load range and wide input variation. In order to get high voltage gain characteristics in a wide input and load ranges, the conventional LLC resonant converter requires a small magnetizing inductance, and a lot of losses by the higher magnetizing current can be generated in the switches and transformer. The proposed LLC resonant converter with two resonant tank circuits and auxiliary switches, even though large magnetizing inductance of the transformer is used, can get the high voltage gain characteristics in a wide input voltage and load ranges. Also, due to the reduced magnetizing current, losses and efficiency characteristics can respectively be reduced and improved. The proposed LLC resonant converter is described and verified through a 500W experimental prototype.

A novel LLC resonant converter for wide input voltage and load range

This paper presents high efficiency LLC resonant converter operating at the fixed switching frequency which is applied for PV PCS (Photovoltaic Power Conditioning System) with wide input-voltage variations. Operating modes and voltage gain analysis of LLC resonant converter with single and two resonant tanks are described. The secondary windings are connected in series for high output voltage as well as high power. The principle of operation modes, voltage gain analysis and efficiency are verified on a 700W for a single LLC resonant tank and a 1kW for two resonant tanks.

LLC resonant converter with wide input voltage and load range at fixed switching frequency

In this paper, a low profile LLC resonant converter with two planar transformers is proposed for a slim SMPS (Switching Mode Power Supply). Design procedures and voltage gain characteristics on the proposed planar transformer and converter are described in detail. Two planar transformers applied to LLC resonant converter are connected in series at primary and in parallel by the center-tap winding at secondary. Based on the theoretical analysis and simulation results of the voltage gain characteristics, a 300W LLC resonant converter for LED TV power module is designed and tested.

A low profile LLC resonant converter using novel planar transformer

Dielectric elastomers (DEs) have been suggested as generators to harvest electrical energy from natural mechanical energy sources, such as human movements and ocean waves. In this study, a donut-shaped DE generator (DEG) has been fabricated and its performance is characterized depending on the stretch deformation. A simple new stretchable electrode system using multi-walled carbon nanotubes has been suggested. Measurements on the resistance, capacitance, and electrical power generation are made depending on the area expansion. The capacitance and harvested energy are parabolically increased with increased area expansions. The theoretical prediction of energy harvesting is in good agreement with measured values of capacitance changes with stretching. FE analysis is also applied for calculation of strains for the DEG to figure out the distribution of strains. It is suggested that the DEG has promising applications in the field of designing an energy harvesting device depending on the type of energy available. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014, 131, 40076.

Eun-Soo Kim

Papers

A ZVZCS PWM FB DC/DC converter using a modified energy-recovery snubber

A novel LLC resonant converter for wide input voltage and load range

LLC resonant converter with wide input voltage and load range at fixed switching frequency

A low profile LLC resonant converter using novel planar transformer

Fabrication and performance of a donut‐shaped generator based on dielectric elastomer