A Novel Control Method for Light-loaded Multiphase Boost Converter with Voltage Multiplier Used as a Front-end of a Grid-Connected Fuel-Cell

Generation
X. Wu, L. Zhang, G. Shen, D. Xu
College of Electrical Engineering Zhejiang University Hangzhou, China xdh@zju.edu.cn
AbstractA method for improving the operation characteristics of the multiphase boost converter integrated with voltage multipliers is presented. The light-load problem of this converter is investigated. The critical condition to maintain a desirable operation even at light load is derived as a guide to design the converter and its control. A novel PWM control method named Alternating Phase Shift (APS) is proposed to assure the good operation even at light-load. Simulations and experimental results prove the theory and the proposed control method.

Adrian Ioinovici
Electrical and Electronics Engineering Department Holon Institute of Technology Holon, Israel adrian@hit.ac.il input current applications, such as the front-end converter of a grid-connected fuel cell generation. Different uses of the interleaving boost converter integrated with voltage multipliers were proposed in [9] and [10] with the likenesses in advantages and problems when in continuous mode (CCM), but it is not clear whether it can work in discontinuous mode (DCM). However, for some applications such as UPS and telecom power supply, the DCM operation will occur when a light load is applied. It is necessary to explore these working situations of the converter to make it more popular to various applications. This paper analyses the light-load operation of this hybrid converter in detail. The switching stages in DCM operation are investigated. It is shown that the voltage stress across each switch of the converter will be increased when the converter operates in traditional interleaved PWM control mode with a light load. The critical condition is derived for the light-load applications in this paper. A novel PWM control method is presented to overcome the light-load problem, and simulations and experimental results confirm the theory. II. A. MULTIPHASE CONVERTER WITH VOLTAGE MULTIPLIERS

I.

INTRODUCTION

High step-up converters are in great demand in applications such as photovoltaic systems, electric vehicles, telecom power supplies, uninterruptable power supplies (UPS), fuel cell generation systems [1]-[2], etc. And the above applications need high step-up ratio and high efficiency, as well as little electromagnetic interference (EMI) noise, less weight, volume and cost. High DC conversion ratios can be achieved by using high frequency isolated transformers, coupled-inductors or switched-capacitors (SC) [1]-[5]. Some hybrid converters formed by cascading the classical converters and switchedcapacitor converters were proposed in recent years, showing that it is possible to obtain high DC gain with high efficiency, low voltage stress, and low EMI [5]-[10]. Among these, one popular implementation is to use the multiphase-interleaving boost converter integrated with voltage multipliers [8]-[10]. It can increase the conversion ratios up to two or more times of classical boost converter, with the same switching duty-cycle, half or less voltage stress on the switches, and reduced ripples in the input current and output voltage of the converter. This topology seems well adapted for high output voltage and high
JOINT CHINA -ISRAEL RESEARCH GRANT

Circuit Description of the Multiphase Converter The multiphase interleaving is a technique frequently used with the power converters in order to reduce the current and voltage ripple, reducing the current level in the power switches and diodes. In fuel cell generation system, the reduced input current ripple might extend the life span of fuel cell. Normally, the power switches in different phases take turns to be active with a phase shift of 2/P (P is the number of parallel phases), or T/P corresponding to the switching period T.

978-1-4577-0541-0/11/$26.00 2011 IEEE

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(a)Stage1, (t0, t1) Fig. 1 Minimum configuration of interleaving boost converter with voltage multipliers

Fig. 1 shows a minimum configuration of this kind of converter, which is composed by two parallel stages of classical boost converter (P=2), and one series multiplier stage (M=1, defined by the number of the multiplier capacitors in series with each switch). The voltage multiplier is composed by the capacitors (C1 and C2) and diodes (DM1 and DM2). The converter has different operation stages when operating in CCM or DCM. In the case of CCM, the voltage of the multiplier capacitors (C1 and C2) is equal to half of the converter output voltage. This is the maximum voltage applied to the power switches [7]-[8]. As there is no discussion on the converter in DCM in previous papers, it is necessary to analyze the stage operation in order to find out the problem when it operates in DCM. B. Operation of the Multiphase Converter in DCM Operation in DCM occurs in two cases, D0.5 and D<0.5. The voltage on the multiplier capacitors may change greatly with normal multiphase interleaving control order, as well as the voltage stress of the switches. 1. Case D>0.5: Considering the utilization of ideal components and duty cycle higher than 0.5, the DCM operation is divided into six operation stages as shown in Fig.2, and the theoretical current waveforms are shown in Fig.3, where T is the switching period. 1) First Stage (t0,t1): Both switches are in conducting state, and the current flows through the input inductors and power switches. All diodes are blocked and the input inductors store energy during this stage. 2) Second Stage (t1,t2): At the instant of t1, switch S1 is turned-off and the energy stored in the inductor L1 is transferred to the output capacitor Co through C1 and D1, as well as to the multiplier capacitor C2 through DM1. The sum of the voltages in two multiplier capacitors is equal to Vo because of the parallel connection with the output capacitor. The voltage applied across the switch S1 is equal to Vc2. 3) Third Stage (t2,t3): When the current in L1 falls down to zero, all diodes are blocked, and only the input inductor L2 stores energy as before. VS1 is equal to the input voltage Vin.

(b) Stage 2, (t1, t2)

(c) Stage 3, (t2, t3)

(d) Stage 4, (t3, t4)

(e) Stage 5, (t4, t5)

(f) Stage 6, (t5, t6) Fig. 2 DCM operation in six operation stages(D>0.5)

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a) First stage, (t0, t1)

(b) Second stage (t1, t2)-1

Fig.3 Main theoretical waveforms of the multiphase converter in DCM with D>0.5

4) Fourth Stage (t3,t4): At the instant of t3, switch S1 is turned-on, and the input inductors store energy as in the first stage. 5) Fifth Stage (t4,t5): At the instant of t4, switch S2 is turnedoff, and the energy stored in the inductor L2 is transferred to the output capacitor Co through C2 and D2, as well as to the multiplier capacitor C1 through DM2. This stage is similar to the second stage, except that the energy stored in L2 increases Vc1 and decreases Vc2 in this stage, doing the opposite in the first stage. Because the rise of Vc1 will turn down the current in L2 faster than that in L1, the multiplier capacitors can limit their voltage unbalance by itself. Hence, the voltage across the switch S1 or S2 is half of the output voltage Vo. 6) Sixth Stage (t5,t6): At the instant of t5, the current in L2 falls down to zero, all diodes are blocked, and only the input inductor L1 is storing energy. This stage will last till the instant of t6, at which a new switching period begins with the next First Stage. 2. Case D<0.5: With duty cycle lower than 0.5, the DCM operation is divided into six operation stages, as shown in Fig. 4. If the voltage on multiplier capacitor does not drop, the theoretical current waveforms can be shown in Fig. 5. 1) First Stage (t0,t1): Both switches are turned-off, the energy stored in the inductor L2 is transferred to the output capacitor Co through C2 and D2, no current flows through the input inductors L1 and all other diodes are blocked. The maximum voltage across the switch is equal to Vo-Vc2.

(b) c) Second stage (t1, t2)-2

d) Third stage (t2, t3) Fig. 4 Stage in DCM operation with D<0.5

2) Second Stage (t1,t2): At the instant of t1, switch S1 is turned-on and the inductor L1 starts to store energy. In the mean time, output diode D2 is blocked, and the multiplier capacitor C1 starts to be charged through DM2 by the current of L2 to maintain the average voltage of the capacitor to be Vo/2, because the discharging of C2 at first stage and the discharging of C1 in last switching period make their voltages a little bit lower than Vo/2. Depending on the energy stored in L2 and the duration of the first stage, if the amperehour charged in C1 is more than its discharge in a switching period, D2 may conduct once again, as shown in Fig.4(c). On the contrary, if the ampere-hour is not sufficient, the voltages of the multiplier capacitors will drop, resulting a higher voltage stress across the switch in the first or forth stage.

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Fig. 6 Stage after the first stage in DCM with D<0.5 and Vc1+Vc2<Vo-Vin

Consequently, different operation stages will appear when the multiphase boost converter operates in DCM. In case of D0.5, the multiplier capacitor voltage will be equal to half of the output Vo. In case of D<0.5, it may decrease greatly depending on the energy stored in the input inductors (that is the result of specific duty cycle D). It is undesirable for the multiplier capacitor voltage to decrease because it will increase the voltage stress of the main switches. C. Critical Condition of the Duty Cycle to Maintain the Capacitor Voltages in DCM As mentioned above, in order to maintain voltage of the capacitors to be half of the output voltage in the normal operating multiphase interleaving boost converter with multiplier capacitors, it is necessary to limit the duration of the first or the fourth stage, in which both switches are turned-off in the case D<0.5 to ensure that the current of the input inductor at the beginning of the next stage (A switch is turned on just at the instant of t1 or t4 ) is sufficient to charge the multiplier capacitor. Since this duration is equal to (0.5D)T, the duty cycle D must not be less than a critical value Dm, with which ampere-hour of the multiplier capacitors in discharging and charging (from t3 to t4 and form t4 to t5, for example.) are equal. Since the multiplier capacitor voltage is equal to (Vo/2), the inductor current falls linearly from the instant of t3 to t5. The critical duty cycle value Dm can be derived as n2 (1) Dm = , (n = Vo Vin ) 2( n 2) Where n is the voltage gain of the converter. III. LIGHT-LOAD PROBLEM AND THE PROPOSED NOVEL SOLUTION

Fig. 5 Main theoretical waveforms of the multiphase converter in DCM with D<0.5

3) Third Stage (t2,t3): At the instant of t2, the current in L2 falls down to zero, all diodes are blocked, and only the input inductor L1 stores energy continually. 4) Fourth Stage(t3,t4): At the instant of t3, both switches are turned-off as in the first stage, the energy stored in the inductor L1 is transferred to the output capacitor Co through C1 and D1, and all other diodes are blocked. The maximum voltage applied across the switch is equal to Vo-Vc1. 5) Fifth Stage(t4,t5): At the instant of t4, switch S2 is turnedon, and the inductor L2 starts to store energy, and the multiplier capacitor C2 is charged depending on the energy in L1. This stage is similar to the second stage, except that the phases and its components are exchanged in positions. 6) Sixth Stage(t5,t6): At the instant of t5, the current in L1 falls down to zero, all diodes are blocked, and only the input inductor L2 is storing energy. This stage will last till the instant of t6, at which a new switching period restart with the next First Stage. Obviously, the energies stored in the input inductors will mainly transferred to the output capacitor in the first or the fourth stage, and the multiplier capacitors will not be charged sufficiently unless the capacitor voltage decreases to a level, on which a new charging stage can occur after the first or the fourth stage as shown in Fig.6. In that case, the inductors may be reverse energized temporarily, and the multiplier capacitor voltage is less than (Vo-Vin)/2. For example, when D<1/3, it can be obtained that the capacitor voltage will drop to (Vo-Vin)/3. This condition is undesirable because it will increase the voltage stress of the main switches.

A. Light-load Problem of the Multiphase Boost Converter with Voltage Multipliers With a light load and constant voltage output, the boost converter will operate in DCM and with a small duty cycle. For multiphase interleaving boost converter with voltage multipliers, there is a problem when operating in light load due to the limitation to the minimum duty cycle. Considering a resistor (R) connected to the converter output, the voltage gain from the input to the output is derived as:

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Vo D2 T R = 1+ 1+ Vin L

(2)

noise may appear as well.

Where, L is the input inductance in each phase. In order to maintain the normal operation of the multiphase converter, the duty cycle must not be less than the critical value, i.e. DDm. From (2), the load should satisfy the following: L (3) R 2 ( n 2 2n ) , (n = Vo / Vin ) DmT However, in some applications such as UPS and telecom power supply, the load may be very light sometimes. And the converter cant be used with desirable switch voltage stress until the light-load problem is solved. B. Traditional Solutions to the Light-load Problem In traditional ways, the solutions to the light-load problem can be considered as the following: 1) Increase the input inductance or the switching frequency. From (3), it is shown that increasing L or decreasing T will relieve the load limitation in the same proportion. In this way, the energy stored in the input inductors decreases during each switching period. However, this method is limited by the components, and the light-load problem has not been solved completely. 2) Use more phases of boost converter integrated with voltage multipliers. The parallel interleaving phases can increase the power rating of the converter and reduce the current and voltage ripples. In the mean time, the phase shift between the phases is reduced, and the requirement of the duty cycle to maintain the multiplier capacitor voltage is also reduced. Hence, lighter load can be connected to the converter output. For example, if three-phase interleaving boost converter is integrated with voltage multipliers, the critical duty cycle and the load to maintain the capacitor voltage are

a)

First stage (t0, t1)

b)

Second stage (t1, t2)

c)

Third stage (t2, t3)

Dm =

n2 , (n = Vo Vin ) 3(n 2)
R 2L ( n 2 2n ) 2 3Dm T

(4) (5)

d)

Fourth stage (t3, t4)

The disadvantage of this method includes the increase of components and the lack of thoroughness to the very light load. 3) Intermittent control for the converter with light load. The Burst-Mode operation or hiccup intermittent control technique is widely used in SMPS for light load condition to meet the requirement of low power consumption [11]. With critical or a bit larger duty cycle and intermittent control, the light-load problem of the converter can be solved with the penalty of larger input current ripple and output voltage ripple, and an acoustic e) Fifth stage (t4, t5) Fig. 7 Stages in DCM operation with APS for light load, (t4, t5) C. Proposed Novel Control Method to Solve the Light-load Problem In this paper, we propose a novel control method to overcome the light-load problem, which is named as Alternating Phase Shift control (APS). In the method,

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multiphase switches are turned on one by one, just at the instant of the previous switch being turned off, so as to charge the multiplier capacitor in the next phase at the beginning of the inductor releasing its stored energy rather than after the stage when all switches are blocked and the stored energy of the inductor is transferred to the output. For this purpose, the PWM switching sequence of the APS control method is as follows: When the converter is operating in DCM and the duty cycle D required by the output power and voltage regulation is less than the critical value Dm or 1/P (P is the phase number if it is chosen), the switching pulses are changed from the traditional multiphase interleaving mode with a fixed phase shift of 2/P one by one or T/P in time domain to a new mode with a floating phase shift being equal to 2 D or DT. And the switching sequence alternates after every switching period in the way that all the multiphase switches move forward except for the first one moving to the end of the sequence. The converter operating with APS control is defined in ten stages within two switching periods (Fig.7), and the theoretical current waveforms are shown in Fig.8.

4) Fourth Stage: At the instant of t3, both switches are turned-off, the energy stored in the inductor L2 is transferred to the output capacitor Co through C2 and D2, and all other diodes are blocked. The maximum voltage applied across the switch is equal to Vo-Vc2. 5) Fifth Stage: At the instant of t4, the current in L2 falls down to zero, all switches and diodes are blocked. 6) Sixth Stage to Tenth Stage: At the instant of t5, the first switching period come to the end, a new switching period begins. But this time S1 lags behind S2 with a phase shift of 2D. Switch S2 is turned-on at t5, the inductor L2 starts to store energy, and all diodes are blocked. The sixth to tenth stages are similar to the first to fifth stages except that the phases and components are changed in positions. Considering the use of ideal components, the capacitor voltages are nearly constant for every two periods, and the current peak of the inductor is IP (IP=VinDT/L). At charging stages (t1,t2) and (t6,t7), the charges through L1 and L2 to the multiplier capacitors are:
2 t2 LI P QL1 = iL1dt = t1 2(VC 2 Vin ) 2 t7 LI P QL 2 = iL 2 dt = t6 2(VC1 Vin )

(6)

At discharging stages (t3,t4) and (t8,t9), the discharges of the multiplier capacitors are:
2 t9 LI P Qd 1 = iL1dt = t8 2(VO VC1 Vin ) 2 t4 LI P Qd 2 = iL 2 dt = t3 2(VO VC 2 Vin )

(7)

Fig. 8 Main theoretical waveforms of the multiphase converter in DCM with APS for light load, D=0.3

1) First Stage: A new switching period starts at the instant of t0. Switch S1 starts to be turned-on, and the inductor L1 stores energy. All diodes are blocked. 2) Second Stage: At the instant of t1, switch S1 is turned-off, and switch S2 is turned-on at the same time, and the inductor L2 starts to store energy. With the proposed APS control, switch S2 lags behind S1 with a phase shift of 2D corresponding to a time interval of DT. The multiplier capacitor C2 is charged through DM1 by the current of L1 to maintain the capacitor voltage. 3) Third Stage: At the instant of t2, the current in L1 falls down to zero, all diodes are blocked, and only the input inductor L2 stores energy continually.

Equation (6) and (7) show that, if VC1+VC2<VO, then QL1+QL2>Qd1+Qd2, meaning that the total charges to C1 and C2 is more than their discharges; Else if (VC1+VC2=VO) and (VC1<VC2), then the charges of (6) can bring C1 a voltage increase which is equal to (QL2-QL1) /( C1+C2), and the discharge of C1 is less than that of C2 from (7). Hence, the capacitor voltages can be automatically adjusted to be VO/2 with APS control. We see that the capacitor voltages are balanced during every two switching periods and they are equal to half of the output voltage. With the proposed APS control, the converter can operate in DCM with small duty cycle, so the light-load problem is solved. The maximum voltage across the switch is limited to half of the output voltage, and the input current and output voltage ripples are reduced. The converter operates with constant switching frequency, being free from any intermittence or acoustic noise. IV. IMPLEMENTATION OF APS METHOD This converter is controlled with two loops based on PI controllers. The outer voltage loop is to stabilize the output voltage, and the inner current loop is to control the input average current, which is vital important for fuel cell generation system. And the output of inner current loop with

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PI controllers is utilized as the duty cycle reference to regulate the converter as shown in Fig.9.

The algorithm of APS in DSP is shown in Fig.10 (a) with four Timers T1, T2, T3 and T4. The four timers use a common number in compare register to achieve four PWM output with the same duty cycle. And there are phase delays related to duty cycle in each timer achieving alternative interleaving of the above PWM. The PWM1 and PWM2 combines to be the PWM control signal for S1, while the PWM3 and PWM4 does the same for S2. The difference between APS and the traditional methods lies in the reverse phase delay of T2 and T3 as shown in Fig.10 (b). V. SIMULATIONS AND EXPERIMENTAL RESULTS A 10kW model of two-phase interleaving boost converter with voltage multipliers is built in ORCAD10.5. It is intended to be used as a front-end dc-dc converter for a grid-connected fuel cell inverter. Vin=100Vdc, and Vo=700V. The switching frequency is 10kHz. L1=L2=200uH, C1=C2=40uF. Fig.11 shows the simulation results of the converter with traditional interleaving PWM control at D=0.3. The multiplier capacitor voltage drops to 200V, resulting in a 500V voltage stress on switch S1. Fig.12 shows the simulation result with APS control at D=0.3. The capacitor voltage is maintained at Vo/2, and the switch voltage Vs1 is similar with the theoretic waveform in Fig.8. A 10kW DSP controlled prototype is built. The components are the same as above. Fig.13 shows the experimental waveform of Vs1 of the converter (80V to 674 V) in DCM without APS control at D=0.457. S1 is turned off at instant of t1 and t6, and it is turned on at t5 and t10. Switch S2 is turned on at t2 and t7, and turned off at t4 and t9. Dm =0.46 by (4). Hence, D<Dm, the capacitor voltage drops to 254V, which is less than Vo/2. It is shown that the maximum switch voltage is equal to Vo-Vc2 which is higher than Vo/2. Fig.14 shows the experimental waveforms of Vgs1 and Vs1 of the converter in DCM with APS control at D=0.2 (120V to 700V). The capacitor voltage is maintained at Vo/2, and the switch voltage Vs1 is in conformity with the theoretic analysis in Fig.8. In order to fully utilizing the APS for full load control of the multiphase boost converter integrated with voltage multiplier, it is important to conduct further research on the stability under step load change. The experiments are shown in Fig.15. It can be seen that the converter could achieve voltage stress balance in each switch under step change with APS control to traditional method or backwards. VI. CONCLUSIONS This paper contributes to investigate the problems of the multiphase boost converter integrated with voltage multiplier when it operates in DCM. From the theoretic analysis, it is shown that the converter cant achieve expected advantages as in CCM when light-load is applied with the traditional control method is adopted. A novel PWM control method named as Alternating Phase Shift (APS) is proposed to solve the problem in the paper. Simulation and experimental results show that the proposed

Fig. 9 Block Diagram of a multiphase converter with voltage multipliers incorporated with APS control

Fig.10 Algorithm to achieve APS and Traditional Method in DSP

According to the analysis in Part III, the voltage imbalance in C1 and C2 only occurs when D<0.5 with traditional 180 degree interleaving method. Therefore, the APS method could be incorporated with the traditional way in order to achieve full load control as shown in Fig.9. When operation with D<0.5 in light load, the APS method will be adopted for control in order to reduce the voltage stress in the switches of the converter. The traditional 180 degree interleaving method will take effect when it operates with D0.5 in heavier load.

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control method can solve the light-load problem well and could be utilized for full load control with lower voltage stress over the switches.
vC1 + vC 2
VS 1 = 500V

Fig. 11 Voltage waveforms of the converter without APS (D=0.3)

vC1 + vC 2
VS 1 = 350V

vC1

Fig.15 Experimental validation under step load changes( 1kW-traditional method, 500W-APS)

vgs1

vgs 2
[1]

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Fig. 12 Voltage waveforms of the converter with APS (D=0.3)

100V/div

Vo VC = 425V

VC = 254V
Vin + (VL1 ) = 168V
Vin = 80V

t0

t 1 t 2 t3
(1 )2 0 0V /div; (2) 2 0V /div

t4 t5

20us/div

t6 t7 t 8

t 9 t10

t11

Fig. 13 Experimental waveform of Vs1 without APS

5 0 us/div

V1

vS 1

350V 120V

V2

v gs 1
V 1 = 350V; V2 = 120V

Fig.14 Experimental waveform of Vs1 with APS

[11] Choi, J.; Jung-won Kim; Dong-young Huh; , "The new technique for the lowest power consumption in the stand-by of power supply," Power Electronics Specialists Conference, 2004. PESC 04. 2004 IEEE 35th Annual , vol.1, no., pp. 741- 746 Vol.1, 20-25 June 20.

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