The Resonant LLC vs.

LCC Converter Comparing Two Optimized Prototypes

Alexander Pawellek, Christian Oeder, Juergen Stahl, Thomas Duerbaum
Chair of Electromagnetic Fields University of Erlangen-Nuremberg Cauerstr. 7, 91058 Erlangen, Germany AbstractDue to the increasingly demand for highly efficient,
cost-effective and low-profile applications, resonant converter topologies are massively gaining in importance. With the LCC and LLC converter, the two most promising topologies of this converter class are presented and compared within this paper. Based on their individual configuration, both converters are analyzed in the time domain revealing the first differences and similarities. Moreover, both converter topologies are optimized with respect to a low-profile notebook adapter specification for 100 W. The main focus is placed on the magnetic design of both transformers. Finally, two prototypes using completely identical layouts are developed and measurement results are discussed concerning best operation point and overall efficiency.

Figure 1. LCC converter with capacitive output filter

I.

INTRODUCTION

Forced by the irresistible pursuit of low cost applications, SMPS designers are chasing after miniaturized and highly efficient converter designs. In order to achieve this goal of compactness, increasing switching frequencies are required. Unfortunately, the combination of high switching frequencies together with hard switched PWM converters suffers from several drawbacks [1], which can normally be eliminated by resonant converters. Consisting of two resonant elements the series-resonant (SRC) and the parallel-resonant converter (PRC) represent the two simplest members of the resonant converter family. Although reducing the reactive currents to a minimum and thus providing excellent part load efficiency, the SRC converter cannot regulate its output voltage in case of no-load condition. On the contrary, using the PRC converter makes handling of no-load situation possible, but changing part load efficiency for the worse at the same time. Hence, resonant converters with at least three or four storage elements can be used in order to avoid these disadvantages [2]. These so called multiresonant converters can be classified by the number, kind and arrangement of their reactive components in the resonant tank. Despite the numerous possible combinations of LC circuits, mostly the LCC [3] and the LLC converter [4] in Fig. 1 and Fig. 2 are proposed by literature.

Figure 2. LLC converter with capacitive output filter

This paper deals with the comparison of the resonant LCC and LLC converter in the case of low-profile applications. In the first step, based on their individual configuration and principle of operation, both converter topologies are analyzed in the time domain. In the second step, two lowprofile prototypes using completely identical layouts are developed and optimized with respect to a typical notebook adapter specification of 100 W. Finally, based on the evaluation of the advantages and disadvantages of each individual converter concerning best operation point, overall efficiency and magnetic design of the transformer, typical application fields are proposed for both topologies. II. ANALYSIS IN THE TIME DOMAIN

There exist several methods for the purpose of analyzing resonant converters [5-7]. Approximations in the frequency domain are the First Harmonic Approximation (FHA) and the extended First Harmonic Approximation (eFHA). While the FHA replaces the nonlinear output stage of the converter

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

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by one single resistor [6], the eFHA introduces an equivalent complex impedance [8]. Since both approximations are based on simplified assumptions [9], calculations with the FHA and eFHA are relatively fast and simple. Nevertheless, these approximations show some differences compared to the exact solution. Thus, the authors used an analysis in the time domain for both converter topologies in order to make an optimal converter design possible [3,4]. Due to the switching actions in the input and output bridge both resonant converters represent nonlinear and time-variant systems, complicating their analysis. However, by splitting their operation into different subintervals, the converters can be mathematically described between transitions. Taking advantage of the fact that the waveforms of resonant converters are antisymmetric with

A. Investigation of the LCC converter In order to derive the exact solution for the LCC converter, the waveforms of all state variables are required. Within subinterval A the diode rectifier blocks forcing the series inductance Ls and the capacitances Cs and Cp to resonant with the unknown starting values
vCs (t 0) vCs 0 , i Ls (t 0) i Ls 0 , vCp (t 0) vCp 0 .

(2)

By using a Laplace transformation together with the normalizations in Table I, the normalized waveforms for subinterval A can be identified to
mCs (t n ) (1 mCs 0
j Ls 0 1

mCp 0 ) (1

) [1 cos( t n )] (

s sin( t n ) mCs 0

(3)

x(t

0)

x(t T )

x(t T 2)

(1)
jLs (tn ) (1 mCs 0 mCp 0 ) 1 sin( tn ) (
jLs 0 cos( tn ) ( L
mCp (t n ) (1 mCs 0 mCp 0 ) (1 ) [1 cos( t n )] (

the consideration of the first half of the switching period is sufficient. Each converter can be described by three equivalent circuits shown in Fig. 3 and Fig. 4, which are further discussed in the following sections. In case of the LCC converter, the secondary side parallel capacitance p is transformed to the primary side of the transformer, resulting in the equivalent capacitance Cp = p/n2 with the transformer turns ratio n.

(4)

j Ls 0

sin( t n ) mCp 0 . s (

(5)

During subinterval B and C the output rectifier conducts and hence, the parallel voltage vCp(t) is clamped to the transformed output voltage nVo. Repeating the Laplace transformation once again for subinterval B and subinterval C this leads to the normalized solution
mCs (tn ) (1 mCs 0 # nM )[1 c tn )] jLs 0 sin(tn ) mCs 0 cos( jLs (tn ) (1 mCs 0 # nM ) sin(tn ) jLs 0 cos(tn )
mCp (tn ) n nM

subinterval A

(6) (7) (8)

subinterval B (+nVo) and C (-nVo) Figure 1. Intervals of the LCC converter

with the upper sign for subinterval B and the lower sign for subinterval C. B. Investigation of the LLC converter Obtaining the normalized waveforms of the LLC converter can be done completely similar to the LCC converter. While no energy is transported to the output, the LLC converter can be characterized by the subinterval A (see Fig. 4) and Lp SDUWLFLSDWHV DW WKH WDQNV RVFLOODWLRQ ZLWK

subinterval A

mCs (tn ) 1 c ( tn ) mCs 0 cos( tn ) cos( (

jLs 0

sin( tn ) (

(9) (10) (11)

jLs (tn ) (1 mCs 0 ) sin( tn ) jLs 0 cos( tn ) ( (

subinterval B (+nVo) and C (-nVo) Figure 4. Intervals of the LLC converter

jLp tn

jLs tn .

For subinterval B and C the diode rectifier is forward biased clamping the voltage across the parallel inductance to
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TABLE I. ABBREVIATIONS AND NORMALIZATIONS circuit variable characteristic impedance resonant frequency output voltage output current series capacitor voltage series inductor current parallel capacitor voltage parallel inductor current switching frequency capacitance ratio inductance ratio
os

TABLE III. IMPORTANT I NTERVAL SEQUENCES (LLC CONVERTER)

tn 0 F F<1 Mode Mode Mode Mode Mode BC BAC BA ABA ABA B B B A A C A A B B C A A ZVS, ZVS, ZVS ZVS ZVS ZCS ZCS boost mode boost and buck operation (nM > 1) mode F>1 Mode CAB C A B ZVS Mode CB C B ZVS

symbol

normalized variable

Zo
1

Ls / Cs
Ls C s 2 f os

M
Jo mCs (t )

Vo Io
vCs (t )

Vo / Vin
I o Z o / Vin vCs (t ) / Vin

buck mode (nM < 1)

iLs (t )
v Cp (t ) iLp (t )

jLs (t ) iLs (t ) Z o / Vin L

mCp (t ) jLp (t ) vCp (t ) / Vin iLp (t ) Z o / Vin

fs

1 / Ts
Cs / C p Ls / L p

f s / f os
1
/( / 1)

vLp(t) = nVo. Hence, the parallel current iLp(t) increases and decreases linearly, respectively.
mCs (tn ) (1 # nM ) [1 cos(tn )] mCs 0 cos(tn )

(12)

jLs 0 sin(tn ) L
jLs (tn ) (1 # nM mCs 0 ) sin(tn ) jLs 0 cos(tn )
jLp (tn ) nM tn nM jLp 0

(13) (14)

The most important mode of the LCC converter for power adaptors is the mode CAB, since ZVS is achieved and circulating currents in the resonant tank are minimized. Nevertheless, the resonant blocking interval A occurs, forcing the converter to operate in the DCM operation mode. Fig. 5. illustrates the schematic waveforms of the state variables for this interval sequence over one switching period. Due to its load independent point, the LLC converter operates with the interval sequence CB almost over the entire load range in case of nominal input voltage. The big advantage of this CCM mode is the fact that no blocking interval is introduced, which causes higher rms currents and hence, reduces the efficiency of the converter. The basic waveforms of the mode CB are exemplified in Fig. 6. Nevertheless, in case of mains dips the operation of the LLC converter switches to the DCM mode BA. III. DESIGN

C. Comparison of the most important modes Finally, combining the different intervals of the resonant LCC and LLC converter, a total of ten important modes can be identified, each consisting of two or three subintervals. For a wide frequency range, the LCC converter has four and the LLC converter six modes of operation, which are of interest. The different modes are specified in Table II and Table III. At the beginning of each high frequency cycle at tn = 0, the input bridge switches to positive supply voltage. With the discontinuous mode (DCM) and the continuous mode (CCM), two general modes of resonant converters are possible. While the DCM has at least one interval, where no energy is transferred to the output, the CCM has a continuous energy transfer. Since for the LCC converter the parallel capacitor must be charged to the other polarity after the zero crossing of the inductor current, the blocking interval A must follow after interval B and C. Therefore, the operation of the LCC converter is restricted to DCM exclusively, while the resonant LLC converter can either operate within the CCM or DCM operation mode.
TABLE II. IMPORTANT INTERVAL SEQUENCES (LCC CONVERTER)
F<1 tn 0 F Mode BAC B A C ZCS buck mode F>1 Mode Mode Mode ABA Mode ABA CAB ACA A A C A B B A C A A B A ZVS, ZCS ZVS, ZCS ZVS ZVS buck (nM < 1) and boost (nM > 1) operation mode

In order to compare the LCC and the LLC converter, two prototypes were designed and built with the same specification according to Table IV. An application scenario typical for notebook adapters was chosen with an input

Figure 5. LCC converter, waveforms mode CAB

Figure 6. LCC converter, waveforms mode CB

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TABLE IV. SPECIFICATION OF THE CONVERTERS input voltage range output voltage output power maximum switching frequency maximum converter height Vi = 250 9 V Vo = 19 V Po = 100 W fmax = 500 kHz hmax = 10 mm

voltage range of 250 V to 400 V and an output voltage of 19 V. The dc-bus voltage is generated by a preregulated ac-dc stage with power factor correction and minimized conducted emissions, in order to fulfill requirements of EMI regulations. The converters provide a maximum output power of 100 W and a half-bridge configuration is used, reducing the effective DC input voltage by half to Vi/2. An important design goal was a height constraint of 10 mm. The resonant tank of the LCC and LLC converter consists of three reactive components. An additional transformer for mains isolation is required. With a proper design of the transformer, the magnetic components of the resonant tank can be integrated within the transformer without any additional magnetic components. This will result in a smaller size and less costs of the converter. A. Design of the LCC converter The resonant tank of the LCC converter consists of two capacitors (Cs, Cp) and one series inductor Ls. Based on the cantilever model of the transformer, Ls can be integrated as the leakage inductance. The magnetizing inductance must be at least a few times greater than the leakage inductance in order not to influence the current and voltage waveforms. Otherwise, this inductance acts as an additional resonant element and the order of the converter is increased to four. According to some calculations, a ratio of ten is sufficient to neglect the influence. The design of the tank of resonant converters starts with the design of the transformer, including the integrated magnetic components. Fig. 7 shows the series inductor current at full load as a function of the series inductance Ls with = 10. The inductor current decreases by increasing the value of Ls. With n 8 the specification cannot be fulfilled anymore at a certain value of the series inductance. The circulating currents must be minimized in order to design the converter with a high efficiency. According to Fig. 7, a turns ratio of n = 7 is chosen as design goal for the transformer together with an inductance value of Ls above 150 H.

For the transformer, a ring core TN32/19/13 [10] is used. To meet the requirements of the 10 mm height constraint, the height of the core is reduced down to 7 mm. Fig. 8 shows the arrangement of the primary side and the secondary side on the core. A rather large distance between primary and secondary is on the one hand necessary in order to fulfill safety requirements, on the other hand high values for Ls can be expected. The transformer data is listed in Table V. The values of the leakage inductance Ls, the magnetizing inductance Lh and transformer turns ratio n are based on the cantilever model of a two winding transformer. Without an airgap, the magnetizing inductance is more than 30 times greater than the leakage inductance Ls and can be neglected. An additional degree of freedom for optimization is the FDSDFLWDQFH UDWLR  $FFRUGLQJ WR )LJ  D UDWLR RI = 11 is used as an optimal value. With denormalization, the values of the capacitors are Cs = 13.6 nF = 6.8 nF + 6.8 nF Cp = 66 nF = 33 nF + 33 nF. (15) (16)

In each case, two capacitors are paralleled, in order not to exceed the maximal current through the capacitors.
TABLE V. TRANSFORMER DATA OF THE LCC CONVERTER Core: Material: Primary side Secondary side Ls = 192 H TN32/19/13, reduced to 7 mm 3F3 Np = 63 Ns = 9 35 x 0.1 mm 90 x 0.1 mm RP = 113.8 P RS = 9.35 P n=7

Lh = 5830 H

Figure 8. Winding structure of the LCC transformer

Figure 7. Series inductor current at full load versus series inductance Ls

Figure 9. Series inductor current at full load versus capacitor ratio

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B. Design of the LLC converter In order to fulfill the specification requirements (see Table IV) two critical conditions have to be met [4]. On the one hand, while operating at the maximum input voltage, a minimum inductance ratio min becomes necessary, making handling of no-load situation possible. On the other hand, in order to guarantee a maximum output power of 100 W, even while driving the LLC converter with its minimum input voltage, the quality factor has to be limited to a maximum value Qmax. Varying the quality factor and the inductance ratio within their valid ranges in Fig. 10 and Fig. 11, the optimum of the normalized design parameters can be identified to
op opt min

model, the values of the series and the parallel inductance can be determined to Ls = 215 H and Lh = 1130 H, resulting in an effective inductance ratio of about = 0.19, which is close to the optimal value. Finally, the used winding structure of the LLC transformer is shown in Fig. 13 and the transformer data is summarized in Table VI. Based on the realized turns and inductance ratio of the magnetic component (see Table VI), the value of the optimum (maximum) quality factor has to be corrected to Qopt = 0.45, including a safety margin of about 10 %. The series capacitance was chosen to Cs = 10nF, in order to gain the optimal quality factor of Qopt = 0.45, approximately. C. Summary Design By using a ring core as transformer geometry for the LCC converter, very low converter heights can be realized. The effort to design the magnetic component is reduced and with a classical wire wound structure, no complicated integrated magnetics are necessary. Without an air gap, fringing field effects, regarding additional proximity losses are avoided. In contrast, the series inductor as well as the parallel inductor has to be integrated within the transformer in the case of the LLC converter. A certain ratio of leakage to main inductance must be set, complicating the design of the magnetic
TABLE VI. TRANSFORMER DATA OF THE LLC CONVERTER Core: Material Primary side Secondary side Ls = 215 H EFD30/15/9 N87 Np = 53 Ns = 5 12 x 0.1 mm 60 x 0.1 mm RP = 464.3 P RS = 2.89 P n = 9.6

(17)

Qopt

Ls C s n 2 RL

Q m ax .

(18)

Fig. 12 shows the rms currents at full load (Po = 100 W). ( The quality factor Q and the inductance ratio are optimized according to (17) and (18), while the rms curves are plotted as a function of the turns ratio n. Taking the minimum of the series, parallel and diode inductor current into account, the optimum of the LLC converter is chosen to nopt = 9.7, p opt = 0.15 and Qopt = 0.35. Based on the normalized design parameters, the magnetic component was designed with respect to the calculated core and winding losses according to [11-13]. In order to obtain a low-profile design of the LLC converter, an EFD30/15/9 was used [14]. Representing the transformer by a cantilever

Lh = 1130 H

Figure 10. rms currents at full load for

= 0.15, n = 10, Vi = 380 V Figure 12. rms currents at full load for Q = Qmax, =
min,

Vi = 380 V

Figure 11. rms currents at full load for Q = Qmax, n = 10, Vi = 380 V

Figure 13. Winding structure of the LLC transformer

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component. An air gap is necessary in order to get a magnetizing inductance in the dimension of the leakage inductance. Little modifications at the transformer result in a large variation of the induction ratio, moving the best operating point and reducing the efficiency of the converter. The voltage transfer functions M = Vo/Vi of both converter topologies are plotted in Fig. 14 and Fig. 15. Additional, the area of operation for the converter design according to Table IV is highlighted in each case. For the LCC converter, a wide frequency span is necessary in order to control the output voltage throughout the complete load and input voltage range. By contrast, the LLC converter operates close to its load independent point and hence, consequences only a narrow variation in the switching frequency. The measured efficiency of the LCC and the LLC converter for the nominal input voltage of Vi = 380 V and at low input voltage of Vi = 300 V is shown in Fig. 16. The LLC converter has an almost flat efficiency curve throughout the complete load range of about 93 %. Only at deep part load, the efficiency drops to 85 %. The behavior can be explained by the voltage transfer function in Fig. 15. With a constant input voltage, the LLC converter is operating only with a small variation in the switching frequency, almost independently from the load. This called load independent point at the nominal input voltage was optimized during the design of the resonant tank resulting in high efficiency. Also the input voltage has only a small influence on the efficiency, whereby the efficiency at low input voltages is a little bit less than at

Figure 16. Efficiency of both resonant converter prototypes

high input voltages. In contrary to the LLC converter, the efficiency of the LCC converter is much smaller and reaches only 88 % at the best operating point. This best operating point with minimized circulating currents is at the minimum input voltage at full load, which is the lower left corner of the operating area in Fig. 14 near the minimum of the blue voltage transfer curve for full load. The switching frequency must be increased for lower loads in a wide range. Since the impedance of the parallel capacitor decreased with increased frequency, more reactive current is necessary in order to control the output voltage. This results in lower efficiency at part load, caused by the high reactive currents circulating in the resonant tank. In contrast, the impedance of the parallel inductor at the LLC converter increases at higher switching frequencies. Less current is necessary through the magnetizing inductance to get the specified output voltage. Another drawback of the LCC converter is the unfavorable influence of the input voltage to the efficiency. The efficiency at the low input is a few percentage points higher than at the high input voltage. However, the converter is operating normally at the nominal input voltage of 380 V with less efficiency and only at mains dips at a lower voltage with an increased efficiency. Both converters use a full bridge rectifier for rectification. A center-tapped rectifier or synchronous rectifier can further improve the efficiency. Pictures of the prototypes of the LCC and LLC converter are shown in Fig. 17 and Fig. 18. Except of the resonant tank, the same layout and the same components are used for both converters. Moreover, Fig. 19 and Fig. 20 show the measured waveforms of the LCC and the LLC converter at the nominal input voltage of Vi = 380 V, while providing an output power of Po = 80 W. The measured waveforms show a good agreement with the simulated ones.

Figure 14. Voltage transfer function (LCC converter)

Figure 17. Prototype of the LCC converter Figure 15. Voltage transfer function (LLC converter)

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Figure 18. Prototype of the LLC converter

By contrast, the design of the resonant tank of the LCC converter is much easier, since only the series inductance has to be integrated as the leakage inductance. While at the LLC converter a certain inductor ratio must be set, a certain capacitor ratio is necessary at the LCC converter simplifying the design process. Since the efficiency increases with falling input voltage, fields of applications are single mains with a limited range of input voltage. Hence, the resonant LCC tank is the preferred solution for electronic ballast for compact fluorescent lamps, where in addition the parallel capacitor provides a current path for filament heating and a sufficient starting voltage for ignition. Additional fields of applications for the LCC converter are high voltage applications. Since there is a transformer with a high turns ratio necessary, the parasitic capacitances on the secondary side are sufficient for acting as the parallel capacitor in the resonant tank. REFERENCES
[1] D. KuebricK 7 'XHUEDXP $ %XFKHU ,QYHVWLJDWLRQ RI 7XUQ-Off %HKDYLRXU XQGHU WKH $VVXPSWLRQ RI /LQHDU &DSDFLWDQFHV 3&,0 Conference, Nuremberg, Germany, May/June 2006 , %DWDUVHK 5HVRQDQW &RQYHUWHU 7RSRORJLHV ZLWK 7KUHH DQG )RXU (QHUJ\ 6WRUDJH (OHPHQWV ,((( Transactions on Power Electronics 9, vol. 1, 1994, pp. 64-73. $ 3DZHOOHN $ %XFKHU 7 'XHUEDXP 5HVRQDQW /&& FRQYHUWHU for low-SURILOH DSSOLFDWLRQV 0(/(&21  - 2010 15th IEEE Mediterranean Electrotechnical Conference, 2010, pp. 1309-1314 C. OedeU $QDO\VLV DQG 'HVLJQ RI D /RZ-3URILOH //& &RQYHUWHU IEEE international Symposium on Industrial Electronics, Bari, Italy, 2010, pp. 3859-3864 $ %XFKHU 7 'XHUEDXP ' .XHEULFK DQG 6 +RHKQH 0XOWLresonant LCC converter - comparison of different methods for the steady-VWDWH DQDO\VLV 3RZHU (OHFWURQLFV 6SHFLDOLVWV &RQIHUHQFH 2008, pp. 1891-1897. & 2HGHU $ %XFKHU - 6WDKO 7 'XHUEDXP &RPSDULVRQ RI Different Design methods for the LLC Converter with Capacitive RXWSXW )LOWHU ,((( :RUNVKRS on Control and Modeling for power Electronics, 2010 6 ' -RKQVRQ DQG 5 : (ULFNVRQ 6WHDG\-state analysis and GHVLJQ RI WKH SDUDOOHO UHVRQDQW FRQYHUWHU ,((( 7UDQVDFWLRQV RQ Power Electronics 3, vol. 1, 1988, pp. 93-104. G. Ivensky, A. Kats, and S. Ben-<DDNRY $Q 5& /RDG 0RGHO RI parallel and Series-Parallel Resonant DC-DC Converters with &DSDFLWLYH 2XWSXW )LOWHU ,((( 7UDQVDFWLRQV RQ 3RZHU (OHFWURQLFV 14, vol. 3, 1999, pp. 515-521. 5 / 6WHLJHUZDOG $ &RPSDULVRQ RI +DOI-Bridge Resonant ConverteU 7RSRORJLHV ,((( 7UDQVDFWLRQV RQ 3RZHU (OHFWURQLFV  vol. 2, 1988, pp. 174-182. Ferroxcube datasheet TN32/19/13. URL: www.ferroxcube.com/prod/assets/tn321913.pdf. 7 'XHUEDXP 0 $OEDFK &RUH /RVVHV LQ 7UDQVIRUPHUV ZLWK DQ $UELWUDU\ 6KDSH RI WKH 0DJQHWL]LQJ &XUUHQW WK (XURSHDQ 3RZHU Electronics Conference EPE, Sevilla, Spain, p. 1171-1176, 1995 0 $OEDFK 7ZR-dimensional calculation of winding losses in WUDQVIRUPHUV VW ,((( 3RZHU (OHFWURQLFV 6SHFLDOLVWV &RQIHUHQFH PESC, Galway, Ireland, paper 41.4, p. 1639-1644, 2000 0 $OEDFK + 5RPDQLWK 7KH LQIOXHQFH RI DLU JDS VL]H DQG winding position on the proximity losses in high frequency tranVIRUPHUV QG ,((( 3RZHU (OHFWURQLFV 6SHFLDOLVWV &RQIHUHQFH PESC, Vancouver, Canada, 2001 Ferroxcube datasheet EFD30/15/9, URL: http : //www .ferroxcube.com/prod/assets/efd30.pdf

Figure 19. Measured waveforms of the LCC converter

[2]

[3]

[4]

[5]

[6] Figure 20. Measured waveforms of the LLC converter

IV. SUMMARY This paper compares the multiresonant LCC and LLC converter with capacitive output filter. In a first step, both converters are analyzed in the time domain revealing the first differences and similarities. In a second step, two low-profile prototypes according to a typical notebook adapter specification for 100 W are developed using completely identical layouts. Based on the obtained results, the LLC converter is a suitable topology for high efficient power adapters, providing a high and nearly constant efficiency throughout the complete load and input voltage range. Since the parallel inductance and the series inductance can be integrated within one single transformer, only an additional series capacitor for the resonant tank is necessary, reducing the component count. Nevertheless, the integration of two magnetics within the transformer complicates its design dramatically, due to the difficult prediction of the magnetizing and leakage inductance. Moreover, even small variations of the inductance ratio result in a rather large drop of the efficiency of this converter.
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[7]

[8]

[9]

[10] [11]

[12]

[13]

[14]