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2 .2
f T (kHz ) ≈ (1)
RT ( kΩ) * CT ( μF )
Figure 2: Simulated output of the converter.
From the application notes, it is recommended by TI to
III. CIRCUIT DESIGN
use RT values between 1kΩ to 100kΩ. The switching
frequency chosen for this project is 50kHz and the duty
The Full-Bridge DC-DC converter will have to maintain a
cycle is 50% or 0.5. RT was chosen to be 5.5kΩ and the
constant 200V DC output with a varying 36-44V DC
CT values were calculated to be 0.1µF. The UC3846
input (40V nominal). This is accomplished by the Pulse
Current Mode PWM controller adjusts the duty cycle of
Width Modulation (PWM) controller. Full bridge
the high and low side outputs to the IR2110 gate drives
topologies have been used for DC-DC converters using
to achieve the 200VDC output. A current mode
a PWM. A full-bridge converter can generate the
controller was chosen instead of a voltage mode control.
highest output power among most converter topologies.
Current mode is used for the following conditions: if the
The full-bridge converter requires a total of four
power supply output is to be a current source or very
switching transistors to perform DC-DC conversion. An
high output voltage. The application is for a DC-DC
converter where the input voltage variation is relatively relatively good cross-regulation, saturable reactor
constrained, modular applications where parallelability controllers are to be used as auxiliary secondary side
with load sharing is required, in push-pull circuits where regulators, and applications where the complexities of
transformer flux balancing is important, and in low cost dual feedback loops and/or slope compensation is to be
applications requiring the absolute fewest components. avoided. After considerations of the requirements for
Considerations of voltage mode should be taken if there this project, the conclusion is that the current mode
are wide input line and/or output load variations control will ease many limitations of voltage mode;
possible, particularly with low line – light load conditions however, it may contribute extra challenges to the
where the current ramp slope is too shallow for stable design. A significant reason to go with current control
PWM operation, high power and/or noisy applications rather than voltage mode control for this circuit is load
where noise on the current waveform would be difficult sharing [12].
to control, multiple output voltages are needed with
V. EXPERIMENTAL REFERENCES
The design was built and tested. In Fig.7, the converter 1. Rik W. De Doncker and Jorg Walter: High-Power
was tested to show the output waveform at maximum Galvanically Isolated DC/DC Converter topology for
power supply potential that was provided in the Power Future Automobiles, IEEE Transactions, 2003.
Electronics laboratory. Fig. 6(a) displays the upper gate 2. Li, Hui, Fang Zheng Peng, and J.S. Lawler: A
drive waveform shown in blue and the output waveform Natural ZVS Medium-Power Bidirectional DC-DC
shown in pink at 5V input and a measured 28.8V output. converter with Minimum Number of Devices, IEEE
Fig. 7(b) displays the stable upper gate drive signal and Transactions on Industry Applications, Vol. 39, No.
the output waveform in pink at an input voltage of 8.78V 2, March/April 2003.
and a measured output of 50V. The output waveform 3. Peng, Fang Z., Fan Zhang, and Zhaoming Qian. A
has a small ripple; however, the results demonstrate the Novel DC-DC Converter for 42V Systems, IEEE
converter is operating as expected. In order to reduce
Transactions, Vol. 0-7803-7754-0/03, 2003.
the ripple, a filter capacitor can be added to the input
4. Fan, Haifeng and Dehong Xu. A Family of PWM plus
and a larger capacitor can be added to the output.
Phase-Shift Bidirectional DC-DC Converters. 35th
Annual IEEE Power Electronics Specialists
V. CONCLUSION Conference, 2004.
5. Xu, Dehong, Chuanhong Zhao, and Haifeng Fan. A
The paper presents detailed modeling, design, and
PWM Plus Phase-Shift Control Bidirectional DC-DC
experimentation of the 1kW bidirectional isolated DC-DC
Converter. IEEE Transactions on Power Electronics,
converter. The design is based on a mix of theoretical
analysis, simulations, and hardware implementations. Vol. 19, No. 3, May 2004.
The detailed design and experiment confirmed the 6. Chen, Gang, Dehong Xu, and Yousheng Wang. A
requirement specifications. Experiments validated the New Family of Soft-Switching Phase-Shift
characteristics and performance shown in the Bidirectional DC-DC Converters. IEEE 2001.
simulations and in the theoretical analysis. A controller 7. Brown, Marty. Power Supply Cookbook Second
has been designed and the simulation results show that Edition. Newnes Butterworth-Heinemann. 2001.
the converter system has a satisfactory transient 8. “Power Electronics: Converters, Applications and
response against load variation and distributed voltage. Design", Mohan, Undeland and Robbins, Wiley,
The simulations and calculations illustrate that the full- 1989.
bridge topology is a suitable choice for this power range. 9. Blake, Carl, IGBT or MOSFET: Choose Wisely,
International Rectifier
Since this is a preliminary prototype, it is recommended 10. IGBTs or MOSFETs: Which is Better For Your
that the next phase is to scale the converter to 10kW Design, Penton Media, Inc., ED Online ID #7501,
with a focus on optimum power density and the use of October 4, 1999,
new power devices such as silicon carbide switches www.elecdesign.com/Articles/Print.cfm?ArticleID=75
and/or diodes. 01
11. Travis, Bill, IGBTs and MOSFETs vie for application,
EDN Magazine, April 29, 1999.
12. A New Integrated Circuit For Current Mode Control. CONTACT
Texas Instruments Unitrode Application Note, U-93,
1999. Dr. Chris Mi, Ph.D,
13. Burt, Rod and R. Mark Stitt. Single-Supply Operation Senior Member IEEE, Member SAE
of Isolation Amplifiers. Burr-Brown Application Assistant Professor
Bulletin, AB-009a, August 1991. Department of Electrical and Computer Engineering
14. Merello, A. A. Rugginenti, and M. Grasso. Using University of Michigan - Dearborn
Monolithic high voltage gate drivers. International 4901 Evergreen Road, Dearborn, MI 48128 USA
Rectifier Design Tips, DT 04-4. Tel: (313)583-6434
15. Adams, Jonathan. Bootstrap Component Selection Email: chrismi@umich.edu
for Control IC’s. International Rectifier Design Tip,
DT-98-2a.
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