The Essence of the Little Box Challenge-Part A: Key Design Challenges &amp; Solutions

Neumayr, Dominik; Bortis, Dominik; Kolar, Johann W.

doi:10.24295/cpsstpea.2020.00014

Cited by 51 publications

(32 citation statements)

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“…Power-dense and efficient AC-DC power conversion [1] is a fundamental building block for grid-interface converters as well as electric drives, and, ultimately, a key to the successful and widespread integration of renewable energy into the energy mix. In particular, kW-scale, single-phase AC-DC converters serve as power-factor-correction (PFC) rectifier input stages for, e.g., data center power supply modules, onboard electric (EV) chargers, and PFC rectifier front-ends for low-power variable speed motor drive systems in heating, ventilation, and air conditioning (HVAC) and servo drives in industry automation and robotics, where nearly 90 % of all drive systems worldwide are below 1 kW in rated power [2].…”

Section: Introductionmentioning

confidence: 99%

Analytical Calculation of the Residual ZVS Losses of TCM-Operated Single-Phase PFC Rectifiers

Haider

Anderson

Nain

et al. 2021

IEEE Open J. Power Electron.

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Triangular-current-mode (TCM) modulation guarantees zero-voltage-switching across the mains cycle in AC-DC power converters, eliminating hard-switching with a minor ≈ 30 % penalty in conduction losses over the conventional continuous current mode (CCM) modulation scheme. TCM-operated converters, however, include a wide variation in both switching frequency and switched current across the mains cycle, complicating an analytical description of the key operating parameters to date. In this work, we derive an analytical description for the semiconductor bridge-leg losses in a TCM AC-DC converter, including the rms current and/or conduction losses, switching frequency, and switching losses. For SiC MOSFETs, we introduce a new loss model for switching losses under zero-voltage-switching, which we call "residual ZVS losses". These losses include the constant Coss losses found in previous literature but must also add, we find, turn-off losses that occur at high switched currents. The existence and modeling of these turn-off losses, which are due to currents flowing through the Miller capacitance and raise the inner gate source voltage to the threshold level and accordingly limit the voltage slew rate, are validated on the IMZA65R027M1H 650 V SiC MOSFET. The complete loss model-and the promise of TCM for high power density and high efficiency-is validated on a 2.2 kW hardware bridge-leg demonstrator, which achieves a peak 99.6 % semiconductor efficiency at full load. The proposed, fully-analytical model predicts bridge-leg losses with only 12 % deviation at the nominal load, accurately including residual ZVS losses across load, modulation index, and external gate resistance.

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Section: Introductionmentioning

confidence: 99%

Analytical Calculation of the Residual ZVS Losses of TCM-Operated Single-Phase PFC Rectifiers

Haider

Anderson

Nain

et al. 2021

IEEE Open J. Power Electron.

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“…where C oss,Q is the charge-equivalent output capacitance of the bridge-leg semiconductor. Further, the zero-crossing detector circuit [8] introduced later requires a small oppositepolarity current for correct operation. Because these effects are implementation-dependent, they are neglected in the theoretical analysis of the different modulation schemes but are revisited in Section IV for the experimental verification.…”

Section: B-tcm and S-tcm Analysismentioning

confidence: 99%

“…With the semiconductor losses and inductor rms current determined for the generalized S-TCM approach, we propose three specific S-TCM implementations with different benefits and downsides. All of these approaches can be implemented with only a zero-crossing detector [8] (i.e. high-bandwidth current measurements are not required) and a simple calculation of switch on-and off-times, as demonstrated in Section IV.…”

Section: S-tcm Modulation Implementationsmentioning

confidence: 99%

“…(5) gives a required turn-off current of 3.0 A to achieve full-ZVS across the full operating range. Similarly, the 200 ns delay in the implemented zero-crossing detector (ZCD) circuit [8] -including the transformer & comparator (80 ns), FPGA read-in and calculation (56 ns), gate driver propagation delay (24 ns), and switch turn-on time This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication.…”

Section: A Switching Loss Characterizationmentioning

confidence: 99%

“…Three-phase rectifier and inverter systems in the kW power range considered here (see Table I) are typically operated in continuous current mode (CCM) [8], where the current is controlled to a low-ripple envelope around the sinusoidal average output current i a . This low-ripple envelope leads to low current stress, but the bridge-leg transistors are each hard-switched for half of the mains cycle.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Novel ZVS S-TCM Modulation of Three-Phase AC/DC Converters

Haider

Anderson

Mirić

et al. 2020

IEEE Open J. Power Electron.

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For three-phase AC-DC power conversion, the widely-used continuous current mode (CCM) modulation scheme results in relatively high semiconductor losses from hardswitching each device during half of the mains cycle. Triangular current mode (TCM) modulation, where the inductor current reverses polarity before turn-off, achieves zero-voltage-switching (ZVS) but at the expense of a wide switching frequency variation (15× for the three-phase design considered here), complicating filter design and compliance with EMI regulations. In this paper, we propose a new modulation scheme, sinusoidal triangular current mode (S-TCM), that achieves soft-switching, keeps the maximum switching frequency below the 150 kHz EMI regulatory band, and limits the switching frequency variation to only 3×. Under S-TCM, three specific modulation schemes are analyzed, and a loss-optimized weighting of the current bands across load is identified. The 2.2 kW S-TCM phase-leg hardware demonstrator achieves 99.7 % semiconductor efficiency, with the semiconductor losses accurately analytically estimated within 10 % (0.3 W). Relative to a CCM design, the required filter inductance is 6× lower, the inductor volume is 37 % smaller, and the semiconductor losses are 55 % smaller for a simultaneous improvement in power density and efficiency.

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Intelligent System for Switching Modes Detection and Classification of a Half-Bridge Buck Converter

Fernández-Serantes

Casteleiro‐Roca

Nováis

et al. 2021

Sustainable Smart Cities and Territories

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The Essence of the Little Box Challenge-Part A: Key Design Challenges & Solutions

Cited by 51 publications

References 0 publications

Analytical Calculation of the Residual ZVS Losses of TCM-Operated Single-Phase PFC Rectifiers

Analytical Calculation of the Residual ZVS Losses of TCM-Operated Single-Phase PFC Rectifiers

Novel ZVS S-TCM Modulation of Three-Phase AC/DC Converters

Intelligent System for Switching Modes Detection and Classification of a Half-Bridge Buck Converter

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