Wilson Eberle

A High-Performance Single-Phase Bridgeless Interleaved PFC Converter for Plug-in Hybrid Electric Vehicle Battery Chargers

In this paper, a new front end ac-dc bridgeless interleaved power factor correction topology is proposed for level II plug-in hybrid electric vehicle (PHEV) battery charging. The topology can achieve high efficiency, which is critical for minimizing the charger size, PHEV charging time and the amount and cost of electricity drawn from the utility. In addition, a detailed analytical model for this topology is presented, enabling the calculation of the converter power losses and efficiency. Experimental and simulation results are included for a prototype boost converter converting universal ac input voltage (85-265 V) to 400 V dc output at up to 3.4 kW load. The experimental results demonstrate a power factor greater than 0.99 from 750 W to 3.4 kW, THD less than 5% from half load to full load and a peak efficiency of 98.9% at 70 kHz switching frequency, 265 V input and 1.2 kW load.

An LLC Resonant DC–DC Converter for Wide Output Voltage Range Battery Charging Applications

In this paper, resonant tank design procedure and practical design considerations are presented for a high performance LLC multiresonant dc-dc converter in a two-stage smart battery charger for neighborhood electric vehicle applications. The multiresonant converter has been analyzed and its performance characteristics are presented. It eliminates both low- and high-frequency current ripple on the battery, thus maximizing battery life without penalizing the volume of the charger. Simulation and experimental results are presented for a prototype unit converting 390 V from the input dc link to an output voltage range of 48-72 V dc at 650 W. The prototype achieves a peak efficiency of 96%.

Evaluation and Efficiency Comparison of Front End AC-DC Plug-in Hybrid Charger Topologies

As a key component of a plug-in hybrid electric vehicle (PHEV) charger system, the front-end ac-dc converter must achieve high efficiency and power density. This paper presents a topology survey evaluating topologies for use in front end ac-dc converters for PHEV battery chargers. The topology survey is focused on several boost power factor corrected converters, which offer high efficiency, high power factor, high density, and low cost. Experimental results are presented and interpreted for five prototype converters, converting universal ac input voltage to 400 V dc. The results demonstrate that the phase shifted semi-bridgeless PFC boost converter is ideally suited for automotive level I residential charging applications in North America, where the typical supply is limited to 120 V and 1.44 kVA or 1.92 kVA. For automotive level II residential charging applications in North America and Europe the bridgeless interleaved PFC boost converter is an ideal topology candidate for typical supplies of 240 V, with power levels of 3.3 kW, 5 kW, and 6.6 kW.

An Automotive Onboard 3.3-kW Battery Charger for PHEV Application

An onboard charger is responsible for charging the battery pack in a plug-in hybrid electric vehicle (PHEV). In this paper, a 3.3-kW two-stage battery charger design is presented for a PHEV application. The objective of the design is to achieve high efficiency, which is critical to minimize the charger size, charging time, and the amount and cost of electricity drawn from the utility. The operation of the charger power converter configuration is provided in addition to a detailed design procedure. The mechanical packaging design and key experimental results are provided to verify the suitability of the proposed charger power architecture.

A Practical Switching Loss Model for Buck Voltage Regulators

In this paper, a review of switching loss mechanisms for synchronous buck voltage regulators (VRs) is presented. Following the review, a new simple and accurate analytical switching loss model is proposed for synchronous buck VRs. The model includes the impact of common source inductance and switch parasitic inductances on switching loss. The proposed model uses simple equations to calculate the rise and fall times and piecewise linear approximations of the high-side MOSFET voltage and current waveforms to allow quick and accurate calculation of switching loss in a synchronous buck VR. A simulation program with integrated circuit emphasis (Spice) simulations are used to demonstrate the accuracy of the voltage source driver model operating in a 1-MHz synchronous buck VR at 12-V input, 1.3-V output. Switching loss was estimated with the proposed model and compared to Spice measurements. Experimental results are presented to demonstrate the accuracy of the proposed model.

A Current Source Gate Driver Achieving Switching Loss Savings and Gate Energy Recovery at 1-MHz

In this paper, a new current source gate drive circuit is proposed for power MOSFETs. The proposed circuit achieves quick turn on and turn off transition times to reduce switching loss and conduction loss in power MOSFETs. In addition, it can recover a portion of the CV gate energy normally dissipated in a conventional driver. The circuit consists of four controlled switches and a small inductor (typically 100 nH or less). The current through the inductor is discontinuous in order to minimize circulating current conduction loss. This also allows the driver to operate effectively over a wide range of duty cycles with constant peak current-a significant advantage for many applications since turn on and turn off times do not vary with the operating point. Experimental results are presented for the proposed driver operating in a boost converter at 1 MHz, 5 V input, 10 V/5 A output. At 5 V gate drive, a 2.9% efficiency improvement is achieved representing a loss savings of 24.8% in comparison to a conventional driver.

An automotive on-board 3.3 kW battery charger for PHEV application

An on-board charger is responsible for charging the battery pack in a plug-in hybrid electric vehicle (PHEV). In this paper, a 3.3kW two stage battery charger design is presented for a PHEV application. The objective of the design is to achieve high efficiency, which is critical to minimize the charger size, charging time and the amount and cost of electricity drawn from the utility. The operation of the charger power converter configuration is provided in addition to a detailed design procedure. The mechanical packaging design and key experimental results are provided to verify the suitability of the proposed charger power architecture.

Optimal Design of Resonant Gate Driver for Buck Converter Based on a New Analytical Loss Model

In this paper, the advantages of a new resonant driver are verified thoroughly by the analytical analysis, simulation and experimental results. A new accurate analytical loss model of the power metal oxide semiconductor field effect transistor driven by a current-source resonant gate driver is developed. Closed-formed analytical equations are derived to investigate the switching characteristics due to the parasitic inductance. The modeling and simulation results prove that compared to a voltage driver, a current-source resonant driver significantly reduces the propagation impact of the common source inductance during the switching transition at high (>1 MHz) switching frequency, which leads to a significant reduction of the switching transition time and the switching loss. Based on the proposed loss model, a general method to optimize the new resonant driver is proposed and employed in the development of a 12 V synchronous buck voltage regulator (VR) prototype at 1 MHz switching frequency. The level-shift circuit and digital implementation of complex programmable logic device (CPLD) are also presented. The analytical modeling matches the simulation results and experimental results well. Through the optimal design, a significant efficiency improvement is achieved. At 1.5 V output, the resonant driver improves the VR efficiency from 82.7% using a conventional driver to 86.6% at 20 A, and from 76.9% using a conventional driver to 83.6% at 30 A. More importantly, compared with other state of the art VR approaches, the new resonant driver is promising from the standpoints of both performance and cost-effectiveness.

A New Digital Control Algorithm to Achieve Optimal Dynamic Performance in DC-to-DC Converters

In this paper, a new optimal control algorithm is proposed to achieve the best possible dynamic performance for DC-to-DC converters under load changes and input voltage changes. Using the concept of capacitor charge balance, the proposed algorithm predicts the optimal transient response for a DC-to-DC converter during the large signal load current change, or input voltage change. The equations used to calculate the optimized transient time and the optimized duty cycle series are presented. By using the proposed algorithm, the best possible transient performance, including the smallest output voltage overshoot/undershoot and the shortest recovery time, is achieved. In addition, since the large signal dynamic response of power converters is successfully predicted, the large signal stability is guaranteed. Experimental results show that the proposed method produces much better dynamic performance than a conventional current mode PID controller

A novel EMI filter design method for switching power supplies

This work introduces an improved and simplified method to design electromagnetic interference (EMI) filters for both dc-dc and ac-dc switching power supplies. This method uses the practical approach of measuring the power supply noise spectrum and using the data to calculate the maximum possible magnitude and minimum possible magnitude of the differential mode and common mode noise impedances. The noise impedance magnitude information aids the design of the EMI filter. Phase information for the noise impedance is not required. In addition, information about the topology and control method of the power supply is not needed. This method solves the limitations of existing EMI filter design methods, which are either too complicated to use, or are based on ideal cases that neglect the noise impedance. The analysis and experimental results show that this method can guarantee that the required attenuation can be achieved, especially at low frequencies.