Power Electronics

ECE 534 Project Part 1 Jay Praful Chheda
NORTH CAROLINA STATE UNIVERSITY

ECE 534 – Fundamentals of Power Electronics and Utility Applications
DESIGN & IMPLEMENTATION OF INPUT-PARALLEL OUTPUT-

SERIES BUCK AND HALF-BRIDGE CONVERTER
Author:- Professor:-
JAY PRAFUL CHHEDA Dr .SUBHASHISH BHATTACHARYA
NOVEMBER 17, 2019
I Certify that I have not Received nor Given Unauthorized Aid for this Test.
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Abstract :- (Project Summary)
A study project is carried out in designing the Input-Parallel Output-Series Buck and Half-Bridge
Converter. A detailed analysis of the components required in the operation of this DC-DC Converter is
undertaken. The low to medium voltage DC-DC converters have vast applications in high-speed
switching appliances as well as in the automation industry. This domain of power electronics made a
significant impact in the recent decades, through the implementation of high power Mosfet and
transistors designed and created. Such power Mosfet too are used in the discussed converter and their
implications on the design efficiency have been studied and projected in this report.
The report summarizes the design specifications required for designing a DC-DC based converter and the
trade-offs required to be made in order to commercialize the converter application for a wide use.
Following are the summarized specifications list required in the operation for the converter and a
comparative study of the designed results achieved.
Parameters Specifications Buck Mode Result Step-Up Mode Result Equal Mode
Result
Input Voltage 55-80 V 80 Volt 80 Volt 80 Volt
Output Voltage 50-100V 60 Volt 100 Volt 80 Volt
Output Power 2.5 KW 2.5KW 25KW 25KW
Max Output 1 Amp 1 Amp 1 Amp 1 Amp
Current Ripple
(peak – peak)
Max Output 2 Volts 2 Volts 2 Volts 2 Volts
Voltage Ripple
(peak to peak)
Minimum Buck – 93% 96.19% 96% 97.96%
Efficiency Step –Up- 88%
Equal Mode:- (N/A)
Switching >50Hz 450Khz 450Khz 450 Khz
Frequency
Operating 0 to 45 degree 25 degree 25 degree 25 degree
Temperature Celsius
From this Compliance table we summarize the fact that, the Buck Mode operates at a higher efficiency
than the Step-Up mode. In the report further, the efficiency understanding is detailed with considering 3
different separate operating points taken to understand the behavior of each mode and to extend the
discussion.
The equal mode operates when the Mosfet in the Buck circuit are in continuous conduction mode with
no switching loss and operating at the Maximum duty cycle. In this mode, minimal losses are occurring
and thus this mode operates at the highest efficiency in 450Khz operation of the Converter discussed.
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LIST OF TABLES
Table No Table Title Page No
1. Selection of the MOSFET 11
2. Selection of the Diode 13
3. Transformer Core Design Parameters 18
4. Excel Sheet for Transformer Design Calculation 20
5. Design Constraint Parameters 20
6. Design Constraint for Flux Density 21
7. Design Parameters Achieved for Primary Winding Turns 21
8. Design Parameters Achieved for Primary Winding Wire Size 22
9. Design Parameters Achieved for Secondary Wire Size 23
10. Inductor Design Parameters 25
11. Design Parameters Calculated for Air-Gap Length 26
12. Design Parameters Calculated for Number of Turns 26
13. Design Parameters of the Selected Core(EE70) 27
14. Comparison of Iterations of Inductor 29
15. Selection of the Input Capacitor 30
16. Selection of the Output Capacitor 31
17. Given 3 Operating Points for Buck Mode 32
18. Achieved results for losses in the Buck Mode 32
19. Given 3 Operating Points for Step-Up Mode 46
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20 Achieved Results for Losses in the Step-Up Mode 46
21 Given 3 Operating Points for Equal Mode 65
22 Achieved results for losses in the Equal Mode 65
LIST OF FIGURES
Figure No Figure Title Page No
1 Buck Module Circuit (Simulated in PLECS) 5
2 Buck Module Sub-Circuit1 (Simulated in PLECS) 6
3 Buck Module Sub-Circuit 2(Simulated in PLECS) 6
4 Buck Inductor Current Waveform 8
5 Buck Capacitor Voltage Waveform 8
6 Buck Converter Considering The Losses. 9
7 Half Bridge Module Sub-Circuit 2&4 (Simulated in PLECS) 10
8 Half Bridge Module Sub-Circuit 2&4 (Simulated in PLECS) 12
9 Equal Mode (Simulated in PLECS) 14
10 Average Inductor Current Waveform 15
11 𝐾𝑔𝑓𝑒 design Constraint 17
12 Rms Current Waveform (Transformer) 18
13 Flux Density Constraint of the Selected Core 19
14 Evaluation of Primary Winding Turns 20
15 Evaluation of Secondary Turns 22
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16 Evaluation of Primary Winding Wire Size 22
17 Evaluation of Secondary Wire Size 23
18 Evaluation of Magnetic Winding Inductance 23
19 Evaluation of Magnetic Peak Current 23
20 Evaluation of Winding Resistance 23
21 Evaluation of Magnetic Core Loss 24
22 Evaluation of Magnetic Copper Loss 24
23 Evaluation to determine the Core Constraints 25
24 Evaluation to determine Air-Gap Length 25
25 Equation for Evaluation of number of turns 26
26 Equation to determine the Wire Size of Inductor Winding 26
27 Final Comparison of Projected and Designed value of Inductor Series 26

Resistance
28 Efficiency Plot for 3 different Operating Points combined 32
29 Losses in the Buck Mode 33
30 Open Loop Simulation in PLECS 34
31 Output Voltage Plot 35
32 Output Voltage (Ripple Magnified) Plot 35
33 Output Current (Ripple Magnified) Plot 36
34 Inductor Voltage (Ripple Magnified) 36
35 Efficiency Plot for Variation of load for Nominal Operating Point 37
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36 Loss Distribution (Vin=70 & Vout=60) 38
37 Open Loop Simulation for corresponding operating point 38
39 Output Voltage (Ripple Magnified) Plot 39
40 Output Current (Ripple Magnified) 39
41 Inductor Voltage Plot 40
43 Inductor Current (Ripple Magnified) 41
44 Efficiency Variation 41
45 Loss Distribution (Vin=70 & Vout=50) 42
46 Open Loop Simulation 42
48 Output Voltage (Ripple Magnified) 44
49 Inductor Voltage 44
51 Inductor Current (Ripple Magnified) 45
52 Efficiency Plot 46
53 Step-up Mode different Operating Point Plots 46-65
54 Equal Mode Operating Point (Vin =80 & Vout = 80) Plot 65-70
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Contents
Page No
Abstract I
List of Tables Ii
List of Figures iii
Task 1 Steady State Analysis
Buck Converter Steady State Analysis

1. 1-4
1.1.A Sub-Circuit 1
1.1.B Sub-Circuit 2
1.2 Half-Bridge Converter Steady State Analysis
2. 4-13
1.2.A Sub-Circuit Mode (1,3)
1.2.B Sub-circuit Mode(2,4)
3. 1.3 Equal Mode Steady State Analysis 14-15
Task 2 Selection of Power Switches and Diodes.
2.1 Mosfet Selection

1 2.1.1 Losses in the Buck Mode 17-26
2.1.2 Loss in Step-Up Mode
2.1.3 Loss in Equal Mode
2.2 Diode Selection
2. 2.2.1 Loss in Buck Mode 26-28
2.2.2 Loss in Step-Up Mode
2.2.3 Loss in Equal Mode
3.
2.3 Budgeting of Losses in Different Modes
Task 3 Design of Transformer and Inductor
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3.1 Transformer Designing

3.1.1 Steps used for Designing the Transformer Core
1. 30-40
3.1.2 Magnetizing Inductance & Peak Flux Current
3.1.3 Transformer Magnetic Losses
3.1.4 Budgeting of the Loss
3.2 Buck Inductor Designing
2. 3.2.1 Objective of Designing 40-41
3.2.2 Core Loss Calculation
3.2.3 Design Process Summary
Task 4 Selection of Capacitors
1 4.1 Design of Capacitors in Buck Mode 43-45

2 4.2 Design of Capacitors in Half-Bridge Mode 46-48
3 48-49
4.3 Design of Capacitors in Equal Mode
4
4.4Capacitor Conduction Losses
Task 5 & 6 Calculation of Losses and Efficiencies Open Loop Simulation in PLECS
5.1 Buck Mode

5.1.1 Loss Distribution Data in the Buck Mode
1 5.1.1(A) Nominal Operating Point 51
5.1.1(B) 𝑉𝐼𝑁 = 70 𝑉 & 𝑉𝑂𝑈𝑇 = 60 𝑉
5.1.1© 𝑉𝐼𝑁 =70 V & 𝑉𝑂𝑈𝑇 = 50𝑉
5.2 Step-Up Mode
5.2.1 Loss Distribution Data in the Step-Up Mode
2 5.2.1(A) Nominal Operating Point 51-52
5.2.1(B) 𝑉𝐼𝑁 = 60 𝑉 & 𝑉𝑂𝑈𝑇 = 100 𝑉
5.2.1© 𝑉𝐼𝑁 =60 V & 𝑉𝑂𝑈𝑇 = 80𝑉
3
5.3 Equal Mode
CONCLUSION
REFERENCES 53
APPENDIX AND MATLAB SCRIPT 54-56
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Task 1:- Steady State Analysis:-

The steady state analysis of the given Input Parallel Output Series Buck and Half Bridge
Converter(IPSOBHB) was done considering three modes of Operation viz., Step-Down
Mode(Buck Mode), the Step-Up Mode and Equal Mode of Operation. For this analysis, the non-
idealities such as parasitic and leakage inductance were not included in the circuit model. For the
diodes, Forward voltage drops that account for the Conduction losses have not been considered.
1.1. Buck Converter Steady-State Analysis:- (STEP-DOWN Mode)
Nominal Operating Point:- Vin = 80V; Vo = 60V
After analyzing the buck converter circuit, the Input Voltage is higher than the desired Output
Voltage, S3 switch conducts while the S1 and S2 are switched off. Thus, all input power is
transferred through the Buck Module. The duty ratio associated here is “𝐷𝐵𝑈𝐶𝐾 ” .
R
𝑖𝑠3
R
𝑖𝑖𝑛 𝑖𝑜
𝑖𝐿 𝑖
R
R
R
R
R
𝐶4
R
𝑖𝐶3 R
Figure 1:- Buck Module Circuit (Simulated in PLECS)

We now split the Buck Module Circuit into two sub-circuits for the Steady State Analysis based
on the conduction of the Switch S3 and Diode D5.
1.1.A Sub-Circuit 1:- {0< t <𝑫𝑩𝒖𝒄𝒌 (𝑻𝒔 )}
𝑖𝑠3
𝑖𝑖𝑛 R
R
𝑖𝑜
R
R
𝑖𝐶3 R 𝑖𝐿 𝑖
R
𝐶4
R
R
R
R
Figure 2:- Buck Module Sub-Circuit1 (Simulated in PLECS)

In the Sub-Circuit 1, the MOSFET Switch S3 is switched on. The diode D5 is OFF. Thus there
will be voltage ′𝑉𝑑5′ across the diode. This circuit operated in the time interval from 0 to 𝐷𝐵𝑢𝑐𝑘 (𝑇𝑠 )
duration. The following equations were derived using the analysis of this sub-circuit.
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WITHOUT CONSIDERING LOSSES:- [2]

• 𝑉𝑖𝑛 = 𝑉𝐶3 = 80 𝑉𝑜𝑙𝑡𝑠; 𝑉𝐶4 = 𝑉𝑂𝑈𝑇 = 60Volts ; 𝑉𝑆3 = 0𝑉(since the MOSFET is in closed state)
• 𝑉𝑖𝑛 − 𝑉𝐿 − 𝑉𝑂𝑈𝑇 = 0 ;
• Thus, 𝑉𝐿 = 𝑉𝑖𝑛 − 𝑉𝑂𝑈𝑇 = 20𝑉𝑜𝑙𝑡𝑠;
• 𝑉𝐷5 = −𝑉𝐶3 (𝐵𝑙𝑜𝑐𝑘𝑖𝑛𝑔 𝑉𝑜𝑙𝑡𝑎𝑔𝑒) = −80𝑉𝑜𝑙𝑡𝑠;
• 𝑖𝐶3 = 𝑖𝑖𝑛 − 𝑖𝑆3 ;
• 𝑖𝑆3 =𝑖𝐿 ;
• 𝑖𝐷5 = 0;
1
• 𝑖𝐷1 = 𝑖𝐷2 = 𝑖𝐷3 = 𝑖𝐷4 = 2 ∗ 𝑖𝐿 ;
• 𝑖𝐶4 = 𝑖𝐿 − 𝑖𝑂𝑈𝑇 ;
𝑉
• 𝑖𝑂𝑈𝑇 = 𝑂𝑈𝑇 ;
𝑅
1.1.B Sub-Circuit 2:- {𝑫𝑩𝒖𝒄𝒌 (𝑻𝒔 ) < 𝒕 < 𝑻𝒔 }
𝑖𝑖𝑛 𝑖𝐶4
𝑖𝐿 𝑖𝑂
R
R
R
𝑖𝑑5
𝑖𝐶3
R
Figure 3:- Buck Module Sub-Circuit 2(Simulated in PLECS)

In the Sub-Circuit 2, the MOSFET Switch S3 is switched OFF. The diode D5 is ON. Thus there
will be current ′𝑖𝑑5′ passing through the diode. This circuit operated in the time interval from
𝐷𝐵𝑢𝑐𝑘 (𝑇𝑠 ) to 𝑇𝑠 duration. The following equations were derived using the analysis of this sub-
circuit.
• 𝑉𝑖𝑛 = 𝑉𝐶3 = 80𝑉𝑜𝑙𝑡𝑠; 𝑉𝐶4 = −𝑉𝑂𝑈𝑇 = −(60)Volts;
• 𝑉𝑆3 = 𝑉𝑖𝑛 = 80𝑉𝑜𝑙𝑡𝑠(𝐵𝑙𝑜𝑐𝑘𝑖𝑛𝑔 𝑉𝑜𝑙𝑡𝑎𝑔𝑒)
• 𝑉𝐿 = −𝑉𝑂𝑈𝑇 = −(60)𝑉𝑜𝑙𝑡𝑠;
• 𝑖𝐶4 = 𝑖𝐿 −𝑖𝑂𝑈𝑇
• 𝑖𝐶3 = 𝑖𝐷5 ;
• 𝑖𝑆3 =0;
• 𝑉𝐷5 = 0;
1
• 𝑖𝐷1 = 𝑖𝐷2 = 𝑖𝐷3 = 𝑖𝐷4 = 2 ∗ 𝑖𝐿 ;
𝑉𝑂𝑈𝑇
• 𝑖𝑂𝑈𝑇 = 𝑅
;
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Performing The Volt-Second Balance across the Inductor L gives the expression for 𝑫𝑩𝒖𝒄𝒌 :-
<𝑉𝐿 >= 0 =𝐷𝐵𝑢𝑐𝑘 ∗ (𝑉𝑖𝑛 − 𝑉𝑂𝑈𝑇 ) + (1-𝐷𝐵𝑢𝑐𝑘 )*( −𝑉𝑂𝑈𝑇 )
𝑉𝑂𝑈𝑇
Therefore, 𝐷𝐵𝑢𝑐𝑘 = = 0.75;
𝑉𝐼𝑁
Performing the capacitor charge balance across the capacitors gives the expression:-c
<𝑖𝐶3 > = 0 = 𝐷𝐵𝑢𝑐𝑘 ∗ (𝑖𝑖𝑛 − 𝑖𝑆3 ) + (1 − 𝐷𝐵𝑢𝑐𝑘 ) ∗ ( 𝑖𝐷5 )
Therefore,
−𝐷𝐵𝑢𝑐𝑘 ∗(𝑖𝑖𝑛 −𝑖𝑆3 )
• 𝑖𝐷5 = 1−𝐷𝐵𝑢𝑐𝑘
<𝑖𝐶4 > = 0 = 𝐷𝐵𝑢𝑐𝑘 ∗ (𝑖𝐿 − 𝑖𝑂𝑈𝑇 ) + (1 − 𝐷𝐵𝑢𝑐𝑘 ) ∗ (𝑖𝐿 − 𝑖𝑂𝑈𝑇 )

Therefore,
𝑉𝑂𝑈𝑇
• 𝑖𝐿 = 𝑖𝑂𝑈𝑇 = 𝑅
With the nominal operating point we can further calculate the passive elements such as the Output
Resistance, Buck Inductance, Input and Output Capacitances.
• 𝑃𝑂𝑈𝑇 = 𝐼𝑂𝑈𝑇 × 𝑉𝑂𝑈𝑇 , with the output power given as 2.5 Kilo-watts and Output Voltage as 60
Volts.
We, get 𝐼𝑂𝑈𝑇 = 41.66 𝐴𝑚𝑝𝑠
𝑉𝑂𝑈𝑇 2
• Similarly, 𝑅𝑂𝑈𝑇 = = 1.44Ω
𝑃𝑂𝑈𝑇
• For Calculation of the buck inductance, looking at the Inductor Current Waveform, we get the
equation for the Inductor Ripple current as follows
𝐼𝐿
∆𝐼𝐿
0⬚ 𝑇𝑑5
𝐷𝐵𝑢𝑐𝑘 𝑇𝑠⬚ 𝑇𝑆
𝑖
Fig 4:- Buck Inductor Current Waveform

(𝑉𝐼𝑁 −𝑉𝑂𝑈𝑇 )×𝐷𝐵𝑢𝑐𝑘 ×𝑇𝑆
• ∆𝐼𝐿 = (Peak to Peak Output Inductor Current Ripple)
𝐿
• Now varying the frequency from 60kHz to 100kHz, we get the Minimum value of the
inductance for the maximum Inductor Ripple value of 1Volt.
11 | P a g e
• For 𝑓𝑆 = 60kHz, 85kHz & 100kHz, we get 𝐿𝑀𝐼𝑁 = 0.25mH, 0.176mH & 0.15mH respectively.
∆𝐼𝐿 ×𝑇𝑆
• For calculation of the output Capacitor, 𝐶4 , we use the formula ∆𝑉𝐶4 = ;
8×𝐶4
• Similarly, for 𝑓𝑆 = 60kHz, 85kHz & 100kHz, we get values for 𝐶4 to be 1.04µF, 0.73µF &
0.625µF.
• For the calculation of the input capacitor, 𝐶3 , we have assumed ∆𝑉𝐶3 = 100𝑚𝑉 and use the
formula
𝐼𝑂𝑈𝑇 ×(1−𝐷𝐵𝑢𝑐𝑘 )×𝐷𝐵𝑢𝑐𝑘
• ∆𝑉𝐶3 = ;
𝐶4 ×𝑓𝑆
• For 𝑓𝑆 = 60kHz, 85kHz & 100kHz, we get values for 𝐶3 to be 1.3mF, 0.9mF & 0.78mF.
𝑉𝐶
𝑉𝑐𝑀𝐴𝑋
𝑉𝑐𝑀𝐼𝑁
0 𝑇⬚
𝐷𝐵𝑈𝐶𝐾 𝑇𝑆 𝑇𝑆
Fig 5:- Buck Capacitor Voltage Waveform

WITH CONSIDERING LOSSES:- [2]
Referring to the sub-circuit diagrams above for the Step-Down Modes, we now include the lossy
elements of the Mosfet, Inductor and the forward voltage drops of the diodes in this case Shottky
Diodes Selected. This inclusion of terms change the Duty Ratio value of the Buck Circuit and thus
we get the estimation of the Efficiency at which our given Buck Circuit Operates.
Thus for the Sub-Circuit1:- (Mosfet Switch S3 (On) and Diode D5(Off) & Diodes D1-D4 (On) ):-
The Voltage across Inductor we get is,
𝑉𝐿 = 𝑉𝑔 − (𝐼𝐿 × 𝑅𝑂𝑁 ) − (𝐼𝐿 × 𝑅𝐿 ) − 2𝑉𝐷 − 𝑉𝑂𝑈𝑇 ;
12 | P a g e
Fig 6:- Buck Converter Considering The Losses.
Similarly, for Sub-Circuit 2:- (Mosfet Switch S3(OFF) & Diode D5(ON) & Diodes D1-D4 (ON)):-
The Voltage across the Inductor we get is,
𝑉𝐿 = −(𝐼𝐿 × 𝑅𝐿 ) − 2𝑉𝐷 − 𝑉𝑂𝑈𝑇 − 𝑉𝐷5 ;
Now Applying the Volt-Sec Balance across the Inductor, we get
𝑉
𝑉𝑂𝑈𝑇 +2×𝑉𝐷 +𝑉𝐷5 +𝑅𝐿 ×( 𝑂𝑈𝑇 )
𝑅
𝐷𝐵𝑈𝐶𝐾(𝑁𝐸𝑊) = 𝑉
𝑉𝐺 −𝑅𝑂𝑁 ×( 𝑂𝑈𝑇 ) +𝑉𝐷5
𝑅
With the inclusion of the Values we get for the loss elements, our new value of the Duty Ratio
comes approximately to
𝐷𝑁𝐸𝑊 = 0.772.
The explanation of the values of loss elements considered is explained in the following tasks. We
will incorporate this new value of the Duty Ratio while calculating specifically the conduction
losses across the Mosfet and the Diodes.
1.2 Half-Bridge Converter Steady-State Analysis:- (STEP-UP Mode)
Nominal Operating Point:- Vin = 80V; Vo = 100V
Here as there are two ripple current peaks in one duty cycle, the duty ratio relation in one
switching cycle is 𝑫𝑯𝑩 + (𝑫′𝑯𝑩 ) = 𝟎. 𝟓
For the Half-Bridge Converter due to the presence of two Power Mosfet Switches connected
in a center-tap formations, we have four operating modes in this converter. They are:-
Mode1:- S1=On & S2=OFF
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Mode2:- S1=OFF & S2=OFF

Mode3:- S1=OFF & S2=ON
Mode4:- S1=OFF & S2=ON
Thus Modes 1 and 3 operate in a same manner and Modes 2 and 4 operate in the same manner.
For simplicity, we are only going to do steady state analysis of Mode (1,3) and (2,4) combined
and construct the imply the designing of the converter. However, while calculating the
efficiency of the model, the losses in the other modes will also be considered in the calculation.
In, the Half-Bridge Circuit, we also include a transformer. The transformer helps in isolating
the converter for its operation and also helps in the Boost operation of the Converter. In order
to get the desired results for the efficiency operation in boost mode, we will increase the no of
turns in the transformer winding by a factor of 10 and keeping the turns ratio same. This
practice was observed to be beneficial in allocating and meeting the desired losses in the
transformer.
1.2.A Sub-Circuit Mode (1,3):- {0< t <𝑫𝑯𝑩 (𝑻𝒔 )}

In the Half-Bridge Circuit for Mode 1&3, the MOSFET S2 is OFF. Thus only 0.5 of the input
voltage flows into the primary winding of the transformer. Thus (0.5n) of the Input Voltage
flows into the secondary of the transformer. MOSFET S3 remains ON for the entire period,
however in this operation only diodes D1 & D4 are ON.
Thus, we get the following equation:-
• 𝑉𝑖𝑛 = 80𝑉𝑜𝑙𝑡𝑠; 𝑉𝑂𝑈𝑇 = 100Volts ; (Assumption:- n= );
• 𝑉𝐷5 = 𝑉𝑖𝑛 = 80𝑉𝑜𝑙𝑡𝑠(𝐵𝑙𝑜𝑐𝑘𝑖𝑛𝑔 𝑉𝑜𝑙𝑡𝑎𝑔𝑒)
• 𝑉𝐿 = 𝑉𝐼𝑁 + (0.5 × 𝑛 × 𝑉𝐼𝑁 ) − 𝑉𝑂𝑈𝑇 = 110𝑉𝑜𝑙𝑡𝑠;
• 𝑖𝐶4 = 𝑖𝐿 −𝑖𝑂𝑈𝑇 ;
• 𝑖𝑆3 =𝑖𝐿 ;
• 𝑉𝐷5 = 𝑉𝐼𝑁 ;
• 𝑖𝐷1 = 𝑖𝐷4 = 𝑖𝐿 ;
𝑉
• 𝑖𝑂𝑈𝑇 = 𝑂𝑈𝑇 ;
𝑅
14 | P a g e
𝑖𝑆1
R
R
R
R R 0.5Vin
R
𝑖 1:n
R 𝑖𝑛
R 𝑛 × 0.5𝑉𝐼𝑁
R
𝑖𝐶4
𝑖𝐶3 𝑖𝑆3
R
𝑖𝐿
R
R
Figure 6:- Half-Bridge Module Sub-Circuit 1&3 (Simulated in PLECS)
1.2.B Sub-Circuit Mode (2,4):- {𝑫𝑯𝑩 (𝑻𝒔 ) < 𝒕 < 𝑻𝒔 }:-
𝑖𝑜𝑢𝑡
R
𝑖𝑆3 𝑖𝐿 R
𝑖𝐶4
𝑖R𝑖𝑛 R
𝑖𝐶3
Figure 7:- Half Bridge Module Sub-Circuit 2&4 (Simulated in PLECS)

In the Half Bridge Circuit for Mode 2&4, the MOSFET S1 and S2 both are OFF. Thus only the
operation is carried in the lower portion of the converter which is comprising of the buck designed
inductor and the 4 diode parallel switches connected in the secondary of the open circuited
15 | P a g e
transformer. Thus, the conduction losses in these Modes is the highest as compared to other modes
of Half-bridge converter operations and thus is necessary to limit the duty cycle of this mode to
the lowest so as to operate the converter at the desired specified efficiency rate.
• 𝑉𝑖𝑛 = 80𝑉𝑜𝑙𝑡𝑠; 𝑉𝑂𝑈𝑇 = 100Volts ;
• (Assumption:- n=2. This is calculated at Worst case i.e. 𝑉𝑖𝑛 =55 volts and 𝑉𝑂𝑈𝑇 =100Volts );
• 𝑉𝐷5 = 𝑉𝑖𝑛 = 80𝑉𝑜𝑙𝑡𝑠(𝐵𝑙𝑜𝑐𝑘𝑖𝑛𝑔 𝑉𝑜𝑙𝑡𝑎𝑔𝑒)
• 𝑉𝐿 = 𝑉𝐼𝑁 − 𝑉𝑂𝑈𝑇 = 𝑉𝑜𝑙𝑡𝑠;
• 𝑖𝐶4 = 𝑖𝐿 −𝑖𝑂𝑈𝑇 ;
• 𝑖𝑆3 =𝑖𝐿 ;
• 𝑉𝐷5 = 𝑉𝐼𝑁 ;
1
• 𝑖𝐷1 = 𝑖𝐷2 = 𝑖𝐷3 = 𝑖𝐷4 = 2 ∗ 𝑖𝐿 ;
𝑉𝑂𝑈𝑇
• 𝑖𝑂𝑈𝑇 = ;
𝑅
Performing The Volt-Second Balance across the Inductor L gives the expression for 𝑫𝑯𝑩 :-
<𝑉𝐿 >= 0 =𝐷𝐻𝐵 ∗ ((1 + 0.5)𝑉𝑖𝑛 − 𝑉𝑂𝑈𝑇 ) + (1-𝐷𝐵𝑢𝑐𝑘 )*( 𝑉𝑖𝑛 − 𝑉𝑂𝑈𝑇 )
𝑉𝑂𝑈𝑇
Therefore = 1+(n*𝐷𝐵𝑢𝑐𝑘 );
𝑉𝐼𝑁
WITH CONSIDERING LOSSES:- [2]

Referring to the sub-circuit diagrams above for the Step-Up Modes, we now include the lossy
elements of the Mosfet, Inductor and the forward voltage drops of the diodes in this case Schottky
Diodes Selected. This inclusion of terms change the Duty Ratio value of the Half-Bridge Circuit
and thus we get the estimation of the Efficiency at which our given Half Bridge Circuit Operates.
Thus , for the Sub-Circuit 1:- (Mosfet Switch S3 (ON) and Diode D5(OFF) and Diodes D1-D4
(ON) ):-
The Voltage across Inductor we get is,
𝑉𝐿 = 𝑉𝑔 − (𝐼𝐿 × 𝑅𝑂𝑁𝑆3 ) − (𝐼𝐿 × 𝑅𝐿 ) − 2𝑉𝐷 +(0.5 × 𝑛 × 𝑉𝐼𝑁 ) − (𝐼𝐿 × 𝑅𝑂𝑁𝑆1 ) − 𝑉𝑂𝑈𝑇 ;
Similarly , for Sub-Circuit 2:- (Mosfet Switch S3(OFF) & Diode D5(ON) & Diodes D1-D4
(ON)):-
The Voltage across the Inductor we get is,
𝑉𝐿 = 𝑉𝐼𝑁 − (𝐼𝐿 × 𝑅𝑂𝑁𝑆3 ) − (𝐼𝐿 × 𝑅𝐿 ) − 2𝑉𝐷 − 𝑉𝑂𝑈𝑇 ;
Thus , applying the Volt-Sec Balance across the Inductor, the equation we get is,
16 | P a g e
<𝑉𝐿 >=0=𝑉𝐼𝑁 − 𝑉𝑂𝑈𝑇 − (𝐼𝐿 × 𝑅𝑂𝑁𝑆3 )–(𝐼𝐿 × 𝑅𝐿 ) + (2 × 0.5𝑛)𝐷 × 𝑉𝐼𝑁 − 2(𝑛2 × 𝐼𝐿 × 𝐷 ×

𝑅𝑂𝑁𝑆1 ) − 2(𝑉𝐷 )
Now Applying the Volt-Sec Balance across the Inductor, we get new duty ratio as
𝑉𝐼𝑁 −𝑉𝑂𝑈𝑇 −(𝐼𝐿 ×𝑅𝑂𝑁𝑆3 )−(𝐼𝐿 ×𝑅𝐿 )−2𝑉𝐷
𝐷𝐻𝐵(𝑁𝐸𝑊) = −𝑛×𝑉𝐼𝑁 +2𝑛2 (𝐼𝐿 ×𝑅𝑂𝑁𝑆1 )
With the inclusion of the Values we get for the loss elements, our new value of the Duty Ratio
comes approximately to
𝐷𝑁𝐸𝑊 = 0.432.
The explanation of the values of loss elements considered is explained in the following tasks. We
will incorporate this new value of the Duty Ratio while calculating specifically the conduction
losses across the Mosfet and the Diodes.
1.3 Equal Mode (Steady State Analysis):-
R
R
R
R
R
Fig :- Equal Mode (Simulated in PLECS)

In the Equal Mode, there is only 1 mode of Operation. The Input and the Output Voltage are the
same. This makes the duty cycle operate at Unity. Due to Unity Duty Cycle, the Mosfet Switch
S3, operates in the Conduction State for the entire switching cycle. Thus there is no switching loss
incurred in the Mosfet. However, the diode D5, is off for the entire switching period. This creates
switching loss in the diode. But, as we discuss the designing of the converter further, we have
selected Schottky diode for the operation. The switching losses are thus neglected in the diode as
in the data-sheets the reverse recovery parameters are not mentioned. However, the amount of
losses neglected drastically change the efficiency operation of the Circuit and thus differ from the
practical implementation of the Converter Design.
Duty Cycle (D) for the Equal Mode is 1.
17 | P a g e
Task 2:- Selection of Power Switches and Diodes :-

(2.1) MOSFET SELECTION:-
• While designing the circuit, the entire responsibility of achieving the desired operating
efficiency and loss is based on the rating of the Semiconductor devices i.e. Power Mosfet
and Diodes. As this converter operates at a large frequency, requirement for high speed
Power Mosfet is required.
• Thus, the selection of the Mosfet apart from the high switching speed application, depends
on the Voltage and Current Ratings too. In order to protect the operation of the Mosfet the
Vdss rating is chosen sufficiently higher than the actual voltage rating. Thus , a safety
margin of (1.5) is used in order to determine the Blocking Voltage of the Mosfet used in
the Converter Operation.
• Blocking Voltage of Mosfet 𝑆3 = 80× 1.5 = 120 𝑉𝑜𝑙𝑡𝑠 & S1=S2=80 × 1.5 =
120 𝑉𝑜𝑙𝑡𝑠
• The peak current taken for the MOSFET is 𝑖𝑃𝐸𝐴𝐾 = 𝐼 + ∆𝑖 = 50 + 0.5 = 50.5 𝐴𝑚𝑝𝑠
• For Selecting the Components multiplying the safety margin of 1.5, we get 75 Amps as
the peak current.
• The RMS current taken for the MOSFET is approximately 50.5 Amps.
Fig 8:- Average Inductor Current Waveform
• Thus , after calculating the Blocking Voltages and the required RMS and Peak Currents,
selection of the MOSFET component was based on selecting with the lowest value of
RdsOn possible.
SWITCH S1 AND S2 (HALF BRIDGE MODE):-
At the blocking voltage of 120 Volts and RMS and Peak Currents of approximately 75 Amps,
following are the switches selected for the MOSFET switch S1 and S2
MOSFET Company Part Number Blocking Voltage 𝑅𝐷𝑆(𝑂𝑁) Continuous
(Maximum) Current
1 IXYS IXTN400N15X4 150 Volts 1m Ω 400 Amps
2 Infineon IPT059N15N3 150 Volts 4.25mΩ 155 Amps
3 Infineon IPB036N12N3G 120 Volts 3mΩ 180 Amps
Table 2:- Selection of the MOSFET[3]
18 | P a g e
Here calculating the blocking voltage, the worst case criterion was selected and similar was
for the current calculation. Thus, the MOSFET used for the converter operation for the
Switches S1,S2 & S3, a single MOSFET configuration was used.
The MOSFET selected was then taken of the IXYS Company with the Part number of
IXTN400N15X4. This is because this MOSFET operated at the nominal operating point of the
given converter specifications and the values.
As the specification of this Mosfet Component from the IXYS datasheet, meets the
requirement for both the modes, I am selecting the same Mosfet for both the Operating Modes.
Thus, after selecting the MOSFET of the Step-Up and Step-Down Mode, the switching and
conduction losses were calculated.
(2.1.1) Losses in Buck Mode:-

(Switch S3)
𝑇(𝑟𝑖𝑠𝑒)+𝑇(𝑓𝑎𝑙𝑙)
• Switching Loss :- 𝑃𝑆𝑊 = 𝑉𝐼𝑁 × 𝐼𝑂𝑈𝑇 × 𝑓𝑆𝑊 × ; [4]
2
Here the values are:-

𝑉𝐼𝑁 = 80 𝑉𝑜𝑙𝑡𝑠;
𝐼𝑂𝑈𝑇 = 41.66 (𝐵𝑎𝑠𝑒𝑑 𝑜𝑛 𝑡ℎ𝑒 𝑁𝑜𝑚𝑖𝑛𝑎𝑙 𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑃𝑜𝑖𝑛𝑡) ;
𝑓𝑆𝑊 = 450 Khz
𝑇𝑅𝐼𝑆𝐸 = 22 nsec
𝑇𝐹𝐴𝐿𝐿 = 8 nsec
Thus, the Switching Losses calculated is 𝑃𝑆𝑊 = 22.49 𝑊𝑎𝑡𝑡𝑠.
• Conduction Loss:- 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝐷𝑁𝐸𝑊 × 𝐼𝑜𝑢𝑡 2 × 𝑅𝑜𝑛

= 0.77× 41.662 × 1 × 10−3
𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 1.339 Watts.
(2.1.2) Loss in Step-Up Mode (Half-Bridge):-

(Switch S1 & S2)
Here the Switches S1 and S2 operate simultaneously ON & OFF in the MODE 1& 3.
However, in the Mode 2 & 4, both the switches S1 & S2 are off. Thus, the switching loss in
the MOSFETS will be only for the MODE 1 & 3. The Switch S3 will be ON for the all 4 modes
19 | P a g e
of Half Bridge Circuit. Thus, there will not be any Switching Loss in the Switch S3. Only
Conduction loss will be there for the Switch S3
MODE 1&3:-
𝑇𝑅𝐼𝑆𝐸 +𝑇𝐹𝐴𝐿𝐿
Switching Losses (S1 & S2) = 𝑃𝑆𝑊 = 2× 0.5 × 𝑉𝐼𝑁 × (𝑛 × 𝐼𝑂𝑈𝑇 ) × 𝑓𝑆𝑊 × ; [4]
2
𝑃𝑆𝑊 = 27.00 Watts

Conduction Loss (S1 & S2) = 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 2 × 𝐷𝐻𝐵 × (𝑛 × 𝐼𝑜𝑢𝑡 )2 × 𝑅𝑂𝑁 ;
𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 0.678 Watts
MODE 2&4:-
Both Switch 1 and 2 are OFF.
Conduction Loss (S3) = 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝐼𝑜2 × 𝑅𝑂𝑁 × 𝐷𝐵𝑈𝐶𝐾
Here the Value of 𝑫𝑩𝑼𝑪𝑲 is 1 as the switch is ON for the entire switching cycle.
(2.1.3) Loss in Equal Mode:-

Here only Switch S3 will be conducting for the entire switching cycle period. Thus, there will
be no Switching loss in the Mosfet. Only Conduction loss will take place in the Mosfet Switch
S3. The current flowing in the Switch will be negligible as the sending end and receiving end
voltage are same. Thus, there will be negligible voltage drop in the circuit and thus the
conduction loss for the Converter circuit will be:-
𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝐷(𝐸𝑞𝑢𝑎𝑙) × 𝐼𝑜𝑢𝑡 2 × 𝑅𝑜𝑛 ;
(2.2) DIODE SELECTION:-

• For the Diode Selection, the worst case value selected will be the highest voltage flowing
in the reverse direction during the conduction of the diode.
• For the Buck Mode, the peak voltage is calculated as 𝑉𝑃𝑒𝑎𝑘 = 80 × 1.5 =120 Volts
• The equation for calculating the peak voltage in the Step-Up Mode(Half-Bridge) is 𝑉𝑃𝑒𝑎𝑘 =
𝑉𝑜𝑢𝑡−𝑉𝑖𝑛
= 55.55 𝑉𝑜𝑙𝑡𝑠.
2×𝐷
• Now considering the 1.5 factor multiplier for the safety margin, the Peak Voltage used for
selecting the diode will be 1.5× 55.55 = 83.33𝑉𝑜𝑙𝑡𝑠.
• In the similar fashion while calculating the RMS and the Peak Current in the MOSFET
Selection, for the Diode Selection, the peak current will be 50 Amps. Multiplying with the
safety margin, we get the peak current as 75 Amps. This is the Forward Current of the
diode.
• Thus, selecting the Diodes based on these above calculations, we get
20 | P a g e
Diode Iteration Company Part Forward Forward

Number Voltage Current
(𝑉𝐹 ) (𝐼𝐹 )
1 Preliminary Microsemi APT60S20B(G) 0.8 Volts 75 Amps
Diode (Used for
Half-Bridge)
2 Final SMC 129SPC150/A 0.74 Volts 120 Amps
Diode
Table 3:- Selection of the DIODE [3]
Reason for selecting the Diode Component (SMC-129SPC150/A):-
Here in order to limit the conduction losses in the diode, the diode with the lowest forward voltage
drop is selected. Thus, the diode component from the SMC company is selected.
(2.2.1) Loss in Buck Mode:-

D5:- Switching Loss:- 𝑃𝑆𝑊 = {(𝑉𝐼𝑁 × 𝐼𝐿 × 𝑡𝑅𝑅 ) + (𝑉𝐼𝑁 × 𝑄𝑅𝑅 )}× 𝑓𝑆𝑊 (NEGLECTED)
As the reverse recovery terms are not specified in the given datasheet, the reverse recovery
switching
Conduction Loss:- 𝑃𝐶𝑂𝑁𝐷𝑈𝐶𝑇𝐼𝑂𝑁 = 𝐷′ 𝐵𝑈𝐶𝐾(𝑁𝐸𝑊) × 𝑉𝐷 × 𝐼𝐿 = 0.24× 0.74 × 41.67
𝑃𝐶𝑂𝑁𝐷𝑈𝐶𝑇𝐼𝑂𝑁 = 7.09 Watts

In the Buck Mode, the Diodes (D1, D2,D3,D4) are always Conducting during the entire switching
cycle. Thus the conducting losses in these 4 parallel diodes is
D1 to D4:- Conduction Loss:- 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 2 × 𝑉𝐷 × 𝐼𝐿 × 𝐷𝐵𝑈𝐶𝐾

(Here the value of 𝐷𝐵𝑈𝐶𝐾 is 1 as the diodes are conducting for the entire switching period)
(2.2.2) Step-Up Mode (Half-Bridge):-
MODE (1&3) & (2&4):-
Switching Loss (D2 & D3) and (D1 &D4)= 𝑃𝑆𝑊 = 2 × 2{(𝑉𝐼𝑁 × 𝐼𝐿 × 𝑡𝑅𝑅 ) + (𝑉𝐼𝑁 × 𝑄𝑅𝑅 )}×
𝑓𝑆𝑊
In the datasheet provided in the Appendix of the report, the 𝑄𝑅𝑅 & 𝑡𝑅𝑅 terms are not given.
Thus, considering that there are negligible losses contributed by the switching of the diodes,
the Switching Loss of the Diodes is neglected.
Conduction Loss (Mode 1&3) for rectifier diode D(1&4) = 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 2 × 2 × 𝐷𝐻𝐵 × 𝑉𝐷 ×
𝐼𝐿 ;
21 | P a g e

Similarly, for the Mode 2&4 for rectifier diode D(2&3) :- 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 2 × 2 × 𝐷′𝐻𝐵 × 𝑉𝐷 ×
𝐼𝐿 ;
Here the conduction losses in the Mode(1&3) are less than the conduction losses of the diodes
in the Mode(2&4) because the Duty Cycle is higher for Mode(2&4). Thus, the conduction time
for the diodes is larger in the Mode(2&4) compared to Mode(1&3).
(2.2.3) Loss in Equal Mode:-
Here all the rectifier diode in the parallel operation will be conducting for the entire switching
cycle period. Thus, there will be no Switching loss in the Rectifier Diodes. However, the diode
D5 will be off for the entire time. But we have neglected the diode switching loss caused by
the reverse recovery characteristics in our design. Thus the conduction loss in the diodes
operation in equal mode will be
𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 2 × (𝐷(𝐸𝑞𝑢𝑎𝑙) × 𝐼𝐿 × 𝑉𝐷 );

(2.3) Budgeting of the Losses in different Modes:-
(2.3.1) BUCK MODE:- (Budgeting of Loss)
Till now, the Switching Losses in the Buck Mode which is due to only the Mosfet Switch S3
has been considered. This is because, the diode switching losses has been neglected. Thus, the
total switching loss in Buck Mode for the Nominal Point Operation is
Switching loss = 22.49 Watts
For the Total Conduction Loss, we get conduction loss from the Mosfet Switch S3, Diode D5
and diode D1 to D4.
Total 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 (𝑆𝑤𝑖𝑡𝑐ℎ 𝑆3) + 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 (𝐷𝑖𝑜𝑑𝑒 𝐷5) + 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 (𝐷1,4)
= 1.33 + 7.09 + 61.65
Total 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 70.07 Watts
Thus, the total losses uptill, now corresponds to the switching and the conduction losses of the
Mosfet and the diodes. Thus, the total Loss in the Buck Mode Operation uptill now is 70.07
Watts.
In order to operate the Buck Converter at least Efficiency of 93% , only 7% of the output power
is available to allocate for the losses. Thus 175 Watts is allocated for the total losses occurring
in the Buck Mode Operation.
Now with the Mosfet and the diodes consuming approximately 70 Watts, we have
22 | P a g e
Remaining Loss = Total Allocated Loss – Loss due to Mosfet and Diode
= 175 – 70
Remaining Loss = 105 Watts
Now a fraction of the remaining Loss in the Buck Converter is allocated for the Inductor’s
Magnetic (Core) and Copper Loss and other for the Capacitor’s ESR Losses.
(2.3.2) Step-Up Mode (Half-Bridge):- (Budgeting of Loss)
Till now, the Switching Losses in the Step-Up Mode is due to the Mosfet Switch S1 and S2 in
Mode 3 & 1 respectively. The diode switching losses has been neglected. Thus, the total
Switching Loss which is due to the Mosfet Operation is,
Switching loss = 27 Watts
For the Total Conduction Loss, we get conduction loss from the Mosfet Switch S1 & S2, and
diode D1 to D4. The rectifier conduction loss is distributed in two modes. In the Mode(1,3),
the conduction loss is across Diode D1 & D4. In the Mode(2,4), the conduction loss is across
Diode D2 & D3
Total 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 (𝑆𝑤𝑖𝑡𝑐ℎ 𝑆1 &𝑆2) + 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 (𝐷1,4) + 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 (𝐷2,3)
= 0.625 + 10.04 + 26.95
Total 𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = 37.615 Watts
Thus, the total losses uptill, now corresponds to the Switching and the Conduction losses of
the Mosfet and the diodes. Thus, the total Loss in the Step-Up Mode Operation uptill now is
64.615 Watts.
In order to operate the Half Bridge Converter at least Efficiency of 88% , only 12% of the
output power is available to allocate for the losses. Thus 300 Watts is allocated for the total
losses occurring in the Buck Mode Operation.
Now with the Mosfet and the diodes consuming approximately 65 Watts, we have
Remaining Loss = Total Allocated Loss – Loss due to Mosfet and Diode
= 300 – 65
Remaining Loss = 235 Watts
Now a fraction of the remaining Loss in the Half Bridge Converter is allocated for the
Inductor’s Magnetic (Core) and Copper Loss , Transformer’s Magnetic (Core) & Copper Loss
& other for the Capacitor’s ESR Losses.
23 | P a g e
(2.3.3) Equal Mode :- (Budgeting of Loss)

Here, in the Equal Mode, as no specific criterion is mentioned for achieving a particular mark
of efficiency, we design and operate this mode in a free condition. However, by theory the
efficiency achieved should be greater than the other two modes of operation, as this mode
operates at the least rate of Losses. We will view the results of the efficiencies achieved in
PLECS Simulation In the Task 5.
24 | P a g e
Task 3:- Design of Transformer and Inductor :-

3.1 Transformer Designing:-
As we are designing the circuit for high frequency converter application, we need to make sure
that the magnetic flux density of the designed core is of the optimal value which prevents the
transformer from saturating. While budgeting the core and copper losses, we have to select the
core parameters such that the magnetic losses of the core is at the minimal rate possible. This is
achieved via the 𝐾𝑔𝑓𝑒 transformer designing method described in the Erickson’s Textbook.
The design constraints while calculating the core parameters are:-

Parameters Symbols Units
Copper Wire Resistivity 𝜌 Ω-cm
Transformer Turns Ratio 1: n ---
Winding Fill Factor 𝐾𝑢 ---
Total Power Dissipation 𝑃𝑡𝑜𝑡𝑎𝑙 Watts
Core Loss Exponent 𝛽 ---
Core Cross Sectional Area 𝐴𝑐 𝑐𝑚2
Core Loss Co-efficient 𝐾𝑓𝑒 W/𝑐𝑚−3 𝑇𝛽
Window Area (Core) 𝑊𝐴 𝑐𝑚2
Mean Length Per Turn MLT cm
Total Winding Current (RMS) 𝐼𝑡𝑜𝑡 A
Magnetic Path Length 𝑙𝑚 cm
Peak Ac Flux Density ∆𝐵 T
Wire Area 𝐴𝑤1 , 𝐴𝑤2 …. 𝑐𝑚2
Primary Volt-Sec ƛ Volt-Sec
Table 4:- Transformer Core Design Parameters[1]
(3.1.1) Steps used for Designing the Transformer Core:-

1) Determine the Core Size:-
Fig:- 𝐾𝑔𝑓𝑒 design Constraint [1]
In the above equation, we need to limit the value of the design constraints to a value such that,
the 𝐾𝑔𝑓𝑒 value selected from the Appendix Table D of the Erickson Textbook, is sufficiently
large enough from the left-hand side value in order to prevent the core from getting saturated.
The design constraints are as follows:-
25 | P a g e
• 𝐼𝑇𝑜𝑡𝑎𝑙 = 𝑃𝑟𝑖𝑚𝑎𝑟𝑦 𝑅𝑚𝑠 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 + 𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑅𝑚𝑠 𝐶𝑢𝑟𝑟𝑒𝑛𝑡
Fig:- Rms Current Waveform (Transformer) [1]
From the above equation of the Rms Current, according to the Switching Waveform,
the primary Rms Current calculated is 𝐼𝑃(𝑅𝑀𝑆) = (𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑟𝑒𝑓𝑒𝑟𝑟𝑟𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑃𝑟𝑖𝑚𝑎𝑟𝑦 +
𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝐶𝑢𝑟𝑟𝑒𝑛𝑡) 𝐴𝑚𝑝𝑠.
For the Secondary Rms Current, applying the transformer turn’s ratio principal,
𝐼𝑃(𝑅𝑀𝑆) 𝑛
= ; Thus, the Secondary RMS current we get from the Waveform above is:-
𝐼𝑆(𝑅𝑀𝑆) 1
𝐼𝑆(𝑅𝑀𝑆) = 15.91 𝐴𝑚𝑝𝑠
In order to calculate n, we need to take the ratio of worst case input voltage (minimum) to the
maximum output voltage.
100
Thus, turn’s ratio, n= 55 ≈ 2.
Therefore, we get the Secondary rms current as 15.905 Amps.

Hence the 𝐼𝑇𝑜𝑡𝑎𝑙 = 𝑃𝑟𝑖𝑚𝑎𝑟𝑦 𝑅𝑚𝑠 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 + 𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑅𝑚𝑠 𝐶𝑢𝑟𝑟𝑒𝑛𝑡
= (15.90× 2) + 15.90 + ( 15.90 )
= 63.61 Amps.
In order for the core to not saturate with the highest peak current flowing in the transformer
winding, we need to factor in the safety margin of 1.5
Thus the 𝐼𝑇𝑜𝑡𝑎𝑙 = 63.61 × 1.5
𝐼𝑇𝑜𝑡𝑎𝑙 = 95.415 Amps.
𝑅𝑒𝑎𝑠𝑜𝑛 𝑓𝑜𝑟 𝐼𝑛𝑐𝑟𝑒𝑎𝑠𝑖𝑛𝑔 𝑡ℎ𝑒 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑇𝑢𝑟𝑛𝑠 (𝑘𝑒𝑒𝑝𝑖𝑛𝑔 𝑡ℎ𝑒 𝑟𝑎𝑡𝑖𝑜 𝑠𝑎𝑚𝑒): −
In order to operate the transformer in a realistic condition and to allocate the total losses in the
Transformer while designing, one observation made was regarding the Turns ratio factor.
26 | P a g e
In the Initial Design, the turns ratio chosen was 1:2. And 25 Watts was allocated to the
Transformer’s magnetic Losses. However, the achieved losses were barely 5 watts. This is due
to the fact of designing the Transformer with low no of turns.
Hence a design choice was considered, to increase the no of turns in both the windings keeping
the turns ratio same. Thus the Primary winding turns N1 was selected as 10×(1), i.e. 10 Turns.
In order to keep the turns ratio same, the Secondary Winding turns was changed to 20 turns.
Thus the turns ratio now comes as 10:20, which is the same ratio as before.
Thus, considering the safety of the Transformer losses, in different operating points, a
calculated design choice was to take Total Loss as 100 Watts.
Thus, 𝑃𝑇𝑂𝑇𝐴𝐿 = 100 𝑊𝑎𝑡𝑡𝑠.
An excel sheet was designed for faster Calculation of the design Parameters.
Table 4.1 Excel Sheet for Transformer Design Calculations.

The other given design constraints are:-
Parameters Numerical Value Units
𝐾𝑢 0.6 ----
−6 Ω-cm
𝜌 1.724× 10
𝐼𝑡𝑜𝑡 95.415 Amps
𝛽 2.7 ----
𝐵𝑚𝑎𝑥 0.2 Tesla
𝐾𝑓𝑒 24 W/𝑐𝑚−3 𝑇𝛽
Table 5:- Design Constraint Parameters[1]
27 | P a g e
Thus, putting the values of the above design constraints, we get the first step calculated as
𝐾𝑔𝑓𝑒 ≥ 1.31× 10−6
We match the value constraint calculated above with the Magnetic Core tables in the Appendix
D and selected the POT CORE 1107 as our transformer core. The reason for selecting this core,
is because it is light in weight and the Flux density of the Core∆𝐵, is less than the Maximum
Flux Density given. The next is the major step forward in designing the core, that helps in
maintaining the core from not going into saturation condition.
2) Evaluating the peak AC flux density:-
Fig:- Flux Density Constraint of the Selected Core[1]

The above equation signifies the criterion that is the core selection of the transformer. As we
aim to design the transformer such that the core does not saturate, we need the Flux density of
the core to be less than the Max Flux Density (𝐵𝑀𝐴𝑋 )
Parameters Numerical Value Units

𝜌 1.724× 10−6 Ω-cm
𝜆1 2.4 × 10−5 Volt-Sec
MLT 2.30 cm
𝐼𝑡𝑜𝑡 95.415 Amps
𝑊𝐴 0.055 𝑐𝑚2
𝐴𝐶 0.167 𝑐𝑚2
𝐾𝑓𝑒 24 W/𝑐𝑚−3 𝑇𝛽
𝑙𝑚 1.55 cm
𝐾𝑢 0.6 ----
𝛽 2.7 ----
∆𝐵 0.109
Table 7:- Design Constraints for Flux Density
Thus, with the Core Flux Density ∆𝐵, less than the Maximum Flux Density, the finalized core
is POT CORE 1107.
3. Evaluation of the Primary Winding Turns.
Fig:- Evaluation of the Primary Winding Turns[1]
28 | P a g e
𝑛1 6.72 No of turns
𝜆1 2.45× 10 −5 V-sec
∆𝐵 0.109 Tesla
𝐴𝐶 0.167 𝑐𝑚2
Table 8:- Design Parameters achieved for Primary Winding Turns
With the calculation of the primary no of turns of the winding, we get the estimation of the no
of turns in the secondary winding. This helps in determining the copper losses in the
Transformer.
4. Evaluating Secondary Turns.
Fig:- Evaluation of Secondary Turns[1]
With the above equation, we get the number of turns in the Secondary winding of the
Transformer. This calculations helps in determining the resistance value required to
incorporate the leakage losses in the Transformer which in turn helps in understanding the
loss distribution more clearly.
𝑛2 = 6.72 × 2
𝑛2 = 13.44 𝑡𝑢𝑟𝑛𝑠
5. Evaluating fraction of window area allocated to each winding
𝑛1 ∗ 𝐼1
𝛼1 =
𝑛1 ∗ 𝐼𝑡𝑜𝑡
𝛼1 = 0.501
𝑛2 ∗ 𝐼2
𝛼2 =
𝑛1 ∗ 𝐼𝑡𝑜𝑡
𝛼2 = 0.3342
6. Evaluating Wire Sizes
Fig:- Evaluation of Primary Winding Wire Size[1]
29 | P a g e
𝐴𝑤1 2.46 ∗ 10−3 𝑐𝑚2

𝛼1 0.501 -
𝐾𝑢 0.6 -
𝑊𝐴 0.055 𝑐𝑚2
𝑛1 1.2 turns
Table 9:- Design Parameters Achieved for Primary Winding Wire Size
Thus, the Wire Gauge Selected from the Appendix table of Erickson (American Wire
Gauge Data) is AWG#24 as the wire size matches with our Primary Side Winding.
Fig:- Evaluation of Secondary Wire Size[1]
𝐴𝑤2 82.05 ∗ 10−3 𝑐𝑚2

𝛼2 0.3342 -
𝐾𝑢 0.6 -
𝑊𝐴 0.055 𝑐𝑚2
𝑛2 13.44 Turns
Table 10:- Design Parameters Achieved for Secondary Wire Size
This, the Wire Gauge Selected from the Appendix table of Erickson (American Wire Gauge
Data) is AWG#8 as the wire size matches with our Secondary Side Winding.
(3.1.2 ) Now, the Magnetic Inductance is to be calculated.
Magnetizing Inductance, referred to Winding 1 =
Fig:- Evaluation of Magnetic Winding Inductance[1]

Thus 𝐿𝑀 = 13.5µ𝐻𝑒𝑛𝑟𝑦
The Peak AC Magnetizing Current is given as,
Fig:- Evaluation of the Magnetizing Peak Current[1]

Thus, 𝑖𝑀𝑝𝑒𝑎𝑘 = 0.907 Amps.
30 | P a g e
Now, Calculating the Winding Resistance,
Fig:- Evaluation of the Winding Resistance, [1]
R1 = 0.016 Ω & R2 = 9.6× 10−4 Ω.

(3.1.3) Transformer Magnetic Loss:-
The core selected in the Transformer, during operation incurs some Magnetic loss due to the
leakage flux in the Windings.
Fig:- Evaluation of the Magnetic Core Loss[1]

Thus, with the given Core Parameters, the Magnetic Core Loss in the Transformer is
𝑃𝑓𝑒 = 0.0160 Watts. This number signifies, that we have perfectly achieved the Transformer
Sizing Criterion, by getting the lowest Magnetic Core possible with the given design
parameters.
The Magnetic copper loss in the Transformer is
Fig:- Evaluation of the Magnetic Copper Loss [1]

With N1= 10 turns, the copper loss we get is,
𝑃𝐶𝑈 = 36.70 Watts. (NOTE:- This calculation is for Nominal Operating Point)
The reason for allocating, the total Power Loss in the Transformer for Magnetic Loss as 100
Watts, is because for the Operating Point (𝑉𝐼𝑁 = 60 𝑉𝑜𝑙𝑡𝑠 & 𝑉𝑂𝑈𝑇 = 100 Volts), the copper
loss was approximately 100 Watts.
3.1.4 Budgeting of the Loss:-
Now, after getting the total Magnetic Loss as 36.716 (Core and Copper), we still have 198.28
Watts left. However, our aim, is to design the best efficient converter possible, we can budget
our Inductor and Capacitor Appropriately.
31 | P a g e
3.2 Buck Inductor Designing:-

3.2.1 Objective of designing the Inductor operating in a buck configuration:-
The single phase buck controllers work well for low voltage converter applications with an enough current
value. However, the power dissipation and efficiency starts to become an issue when the load output voltage
is low and the output current requirements are high enough. Thus, designing the Inductor in this type of
Step-Down Mode circuit would give the freedom to minimize the losses in the conduction of the Inductor
by adjusting the series resistance across the Inductor Winding. [6]
However, in order to achieve minimal losses in the Inductor, it is necessary to select the core for the Inductor
which does not violate the Max Flux Density value 𝐵𝑀𝐴𝑋 = 0.2𝑇𝑒𝑠𝑙𝑎 and the (Peak-to-Peak)Inductor
current ripple of 1A. While Selecting the core of the inductor certain parameters are to be kept in mind.
Following the standard Kg method for designing the Inductor, these are the parameters:-
Parameters Symbols Units

Wire Resistivity ƍ Ω-cm
Peak Winding Current 𝐼𝑀𝐴𝑋 Ampere
Inductance L Henry
Winding Resistance 𝑅𝐿 Ω(ohm)
Winding Fill Factor 𝐾𝑈 ------
Max Flux Density 𝐵𝑀𝐴𝑋 Tesla
Core cross-section Area 𝐴𝐶 𝑐𝑚2
Core Window Area 𝑊𝐴 𝑐𝑚2
Mean Length Per Turn MLT Cm
Table 11:- Inductor Design Parameters[1]
Here the parameters have units in centimeters in order to get the exact value for matching the equivalent
suitable core for the Inductor.
Step 1:- (Determining the core size of the Inductor)
Here we need to design the inductor based on satisfying the inequality given below. The only design
constraints here which can be changed and varied are the Inductance Value, Rms Current and the series
resistance of the winding.
Fig:- Equation to Determine the Core constraint[1]
Step 2:- (Determining the air gap length)
32 | P a g e
Fig :- Equation to determine the Air-Gap Length[1]
𝑙𝑔 7.99× 10−3 Meter

𝜇𝑜 4𝜋 × 10−7 H/m
L 33𝜇𝐻
𝐼𝑚𝑎𝑥 50A
𝐵𝑚𝑎𝑥 0.2T
AC 3.24 𝑐𝑚2
Fig:- Design Parameters Calculated for the Air-Gap Length
The above parameters are the specifications of the selected core and on that values, we design the length
of the air gap needed in order to prevent from the saturation of the core. These values are the based on
the operation of the inductor in the specified operating range given.
Step 3:- (Determining the number of turns)
Fig:- Equation for Evaluation of number of turns. [1]
N 38.58 (Approximated to 39 turns

L 50𝜇𝐻
𝐼𝑚𝑎𝑥 50 Amps
𝐵𝑚𝑎𝑥 0.2 Tesla
AC 3.24 𝑐𝑚2
Table 12:- Design Parameters Calculated for number of turns.
These number of turns, basically decide the series winding value required to be taken in order to limit the
copper losses in the Inductor. As our primary objective is to limit the size and weight of the Inductor to be
deigned, the number of turns needs to be minimized as possible.
Step 4:- (Evaluate the Wire Size):-
Fig:- Equation to determine the Wire Size of the Inductor Winding. [1]
The winding area needs to be selected with the least possible copper area in order to limit the losses.
After calculating the winding area, the last part of the design calculation are the core and the copper
losses occurred in the designed Inductor. Before that, the designer must be sure of the series resistance
value chosen to operate the Inductor at the selected core parameters. Thus, a check for the series
resistance is required.
33 | P a g e
Fig:- Final Comparison of the Projected and Designed Value of Inductor Series Resistance. [1]
Substituting the values of the design parameters in order to calculate the series resistance, we get the
matched value of 3.9
Calculation of the Losses in the Inductor:-

3.2.2 Core Loss:- (𝑷𝑪𝑶𝑹𝑬 ):-
The magnetic loss in the Inductor Core is expressed in terms of the core parameters affecting the size of
the Inductor:-
𝑃𝐶𝑂𝑅𝐸 :- 𝑃𝑓𝑒 = (𝐾𝑓𝑒 × 𝐵𝛽 𝑀𝐴𝑋 × 𝐴𝐶 × 𝐿𝑚 ) Watts.
And the Copper loss in the Inductor winding is given as
𝑃𝐶𝑢 : − (𝐼𝑚𝑎𝑥 2 × 𝑅𝐿 ) Watts.
3.2.3 The design process summary:-

After understanding the design process of the Inductor and its operation factors, I first calculated
the required RMS current flowing in the Buck Circuit.
The Maximum rms current is calculated as follows:-
Thus, putting the value of the Inductor Current
I and the ripple value, we get the Inductor
RMS value as 51 Amps .
Initially the design choice was for operating the converter at 100Khz, for a low switching loss by
operating at the lowest possible frequency. Thus, the calculated Inductance value for 100Khz of
Switching Frequency was:-
15
= 0.15× 103 𝐻𝑒𝑛𝑟𝑦.
𝐹𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦
Therefore, we get the value of the Inductance as L=0.15× 103 𝐻𝑒𝑛𝑟𝑦.
We know the resistivity of the copper is 1.724× 10−6 Ω − cm.
Finally, as we are designing the Inductor, to get a better core value, the design choice for the Series
resistance winding is taken as 7. 2 × 10−3 Ω.
After putting the data in the Step 1 equation, the Kg value constraint was approximately 6.50 𝑐𝑚5 .
This calculated value of the Kg, restricted the entire design process, as referring from the core data
tables in the Textbook, there was no core matching the constraint value at this low frequency
operation.
The Kg value calculated above was high and thus no given core value could function the Inductor
operation at such value. In order to limit the value of the Kg constraint, the Switching frequency
needed to be increased. However, the restriction in increasing the frequency was for the selected
34 | P a g e
semiconductor components. The MOSFET selected, operated at the maximum frequency of

1MHz. Thus, the preferred value still, at which the frequency could be increased was approximated
as 900kHz. However, care was also required to be taken in operating the entire converter at the
lowest possible switching losses. Thus, after gradually increasing the frequency in an interval of
50Khz, the best value at which the core was matched in the Appendix table of Core lists in Erickson
Textbook, was for :-
Kg≥ 5.01𝑐𝑚5 . At this value constraint, the core matched was EE70. Below is the specification
of the finalized core for Inductor Design:-
Core Parameters Values
𝐾𝑔 5.06 (𝑐𝑚5 )
𝐾𝑔𝑓𝑒 75.9 × 10−3
𝐴𝐶 3.24 (𝑐𝑚2 )
𝑊𝐴 6.75 (𝑐𝑚2 )
MLT 14.0 (cm)
𝑙𝑚 18.0 (cm)
Core Weight 280 (g)
Table 13:- Design Parameters of the Selected Core (EE70) [1]
The above core was matched at 450Khz of operating Switching frequency. Thus , the Inductor was
finally designed according to these parameters. The Inductance result at 450Khz operating
frequency was 50 × 10−6 𝐻𝑒𝑛𝑟𝑦.
Formula for Calculation of the Inductance at worst operating point of 𝑉𝐼𝑁 =
80 𝑉( 𝑀𝑎𝑥 𝐼𝑛𝑝𝑢𝑡 𝑉𝑜𝑙𝑡𝑎𝑔𝑒)
& 𝑉𝑜𝑢𝑡 = 50 V ( Min Output Voltage ).
Thus, the Value of Inductance at 450 Khz, we get
(𝑉𝐼𝑁 −𝑉𝑜𝑢𝑡 )×𝐷,𝐵𝑈𝐶𝐾 ×𝑇𝑆
L= ∆𝐼
Inductance L = 50× 10−6 𝐻𝑒𝑛𝑟𝑦
After completing the first step of the design, the EE70 core parameters value were used in order
to calculate the Air gap length, The winding area and the no of turns of the Inductor Winding.
Thus , in order to size the core according to the pre given values of the flux density and winding
factors, there was no path but to increase the frequency in order to lower the Inductance value.
Thus , to summarize the data of the parameters taken in the preliminary design are:-
Parameters Preliminary Final Design Units
Design Values Values
(100KHz Operation) (450Khz
Operation)
Max Rms Inductor Current, 50 50 Ampere
𝑰𝑹𝑴𝑺
Switching Frequency, 𝒇𝑺 100× 103 450× 103 Hertz
−3 −6
Inductance (L) 0.15× 10 50 × 10 Henry
35 | P a g e
Resistivity of Copper Winding, 1.724× 10−6 1.724× 10−6 Ω − cm

ƍ
Max Flux Density, 𝑩𝑴𝑨𝑿 0.2 0.2 Tesla
Series Resistance of Winding, 5.9 × 10−3 5.9 × 10−3 Ω
𝑹𝑳
Winding Fill Factor, 𝑲𝑼 0.6 0.6 -----
Kg 6.50 5.01 𝑐𝑚5
𝑨𝑪 , Cross-Sectional Area ----- (No Core) 3.24 (𝑐𝑚2 )
Air gap length (𝑳𝒈 ) ----- (No Core) 5.56 × 10−3 Metre
No of Turns, n ----- (No Core) 21 -------
𝑾𝑨 , Bobbin Winding Area ----- (No Core) 6.75 (𝑐𝑚2 )
MLT, Mean Length Per turn ----- (No Core) 14.0 (cm)
Core Loss, 𝑷𝑪𝑶𝑹𝑬, (Magnetic ----- (No Core) 18.15 Watts
Loss)
Copper Loss, (𝑷𝑪𝑶𝑷𝑷𝑬𝑹 ) ----- (No Core) 5.20 Watts
Table 14:- Comparison of Iterations of Inductor
36 | P a g e
Task 4:- Selection of Capacitors:-

The Capacitors used in the low-voltage DC-DC converter is to limit the ripple magnitude in the
circuit components and to protect the over-voltage situations. Thus, the selection of the Capacitors
is based on the Output Voltage Ripple.
4.1 Design of Capacitors in Buck Mode:-
The input Capacitor is restricted by the Input Voltage ripple i.e. the Inductor Current Ripple and
the extra voltage ripple caused due to the flow of ripple through ESR.
ESR = Equivalent Series Resistance. This resistance is used to smooth the ripple operation across
the capacitor as well as dissipate the heat loss across the capacitor. However, the power dissipated
is very small, but it is required to limit the ripple current flow into the Inductor:-
C3= Input Capacitor. As this input capacitor has to be large in order to limit the flow of ripple
current into the Inductor, the Capacitance selected is 100µF.
Thus, the component selected is,
Component Company Part Number Capacitance Tan ƃ Voltage
Rating
C3 (Final) TDK B43501A3107M 100 µF 0.4 385 V
C3 TDK B41890A5108M 100 µF 0.2 25 V
(Preliminary)
Table:- Selection of Input Capacitors[3]
Thus, he ESR calculated is
𝑡𝑎𝑛ƃ
ESR =2×𝛱×𝑓×𝐶; [5]
Thus, putting the values of tanƃ =0.4; frequency =450Khz and C=100µF,
We get ESR = 1.4× 10−3 Ω.
C4 = Output Capacitor. The ESR here need to be large enough in order to satisfy the output voltage
ripple requirements.
∆𝐼𝐿 × 𝑇𝑆
𝐶4 = ;
8 × ∆𝑉𝐶4
Thus, the calculated values for the C4 = 0.138 µF.
Thus, the component selected is
Component Company Part Number Capacitance Tan ƃ Voltage
Rating
C4 (Final Vishay 0.138 µF 0.4 150 V
Design) Sprague TE1500-E3-
ND
37 | P a g e
C4 Nichicon 493-1137-ND 0.22 µF 0.6 100V

(Preliminary
Design)
Table:- Selection of Output Capacitors [3]
Thus, the ESR calculated is

𝑡𝑎𝑛ƃ
ESR =2×𝛱×𝑓×𝐶; [5]
Thus, putting the values of tanƃ =0.4; frequency =450Khz and C=0.138µF,
We get ESR = 1.02Ω.
4.2 Design of Capacitors in Step-Up Mode:-
For the Capacitors C1 and C2, we use the same component used for the C3 capacitor. Thus, the
ESR value turns out to be the same.
The output capacitor is the same for the Step-Up Mode which is, C4. Thus, the ESR in this Mode
is also the same.
4.3 Design of Capacitors in Equal Mode:-
Similar to the Buck Mode Configuration, the 2 operating Capacitors are C3 and C4.
Thus, similar calculation for the Equal Mode as Calculated in the Buck Mode.
4.4 Capacitor Conduction Losses:-
The conduction loss in the capacitor is given by the equation,
𝑃𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑖𝑜𝑛 = ∆𝐼𝐿 × (𝐸𝑆𝑅) ; [5]
𝑃𝐶1 = 𝑃𝐶2 = 𝑃𝐶3 = 0.0014 Watts
For the Output Capacitor, the Conduction loss is
𝑃𝐶4 = 0.989 𝑊𝑎𝑡𝑡𝑠
4.4.1 Total Capacitor Conduction Loss in Buck Mode:-
𝑃𝐶3 + 𝑃𝐶4 = 0.9818 Watts
4.4.1 Total Capacitor Conduction Loss in Step-Up Mode:-
𝑃𝐶1 + 𝑃𝐶2 + 𝑃𝐶3 + 𝑃𝐶4 = 0.1062 Watts
4.4.1 Total Capacitor Conduction Loss in Equal Mode:-
𝑃𝐶3 + 𝑃𝐶4 = 0.9818 Watts
38 | P a g e
Task 5 & 6:- Calculation of Losses and Efficiencies Open Loop Simulation in PLECS:-
5.1 Buck Mode :-
5.1.1 Loss Distribution data in the Buck Mode:-
The loss distribution in the Buck Mode is depicted via three different operating point
Simulations.
Mode of Operation Input Voltage Output Voltage
Step-Down Mode 80 Volts 60 Volts
70 Volts 60 Volts
70 Volts 50 Volts
The Losses calculated in all the 3 different operating modes are:-
Losses (Watts) 𝑉𝐼𝑁 = 80𝑉 & 𝑉𝑂𝑈𝑇 = 60𝑉 𝑉𝐼𝑁 = 70𝑉 & 𝑉𝑂𝑈𝑇 = 60𝑉 𝑉𝐼𝑁 = 70𝑉 & 𝑉𝑂𝑈𝑇 =
50𝑉
Mosfet Loss 23.82 Watts 21.15 Watts 25.44 Watts
(SW + Cond)
Diode Loss 68.74 Watts 66.27 Watts 83.99 Watts
(Conduction)
Capacitor Loss 0.994 Watts 0.994 Watts 0.994 Watts
(Conduction)
Inductor 12.49 Watts 12.49 Watts 18.04 Watts
(Magnetic +
Copper)
Total Losses 106.044 Watts 100.904 Watts 128.464 Watts
Fig:- Efficiency Plot for 3 different operating Points combined
5.1.1 (A)Operation at the Nominal Operating Point:-
Input Voltage = 80 Volts ; Output Voltage = 60 Volts

39 | P a g e
LOSSES IN BUCK
Switching Loss Magnetic Core Loss Conduction Loss
Switching
Loss
25%
Magnetic
Core Loss
0%
Conduction
Loss
75%
Fig:- Losses in the Buck mode (Nominal Operating Point)
The Conduction Losses are distributed as:-
Conduction Losses Distribution

Mosfet S3 Diode D5 Rectifier Diodes Inductor Capacitor (C3 &C4)
0.99 1.336
7.09
12.49
61.65
These data are for the Nominal Operating Point. The different losses related to the
components are :-
40 | P a g e
LOSSES IN BUCK (𝑉_𝐼𝑁=80𝑉 & 𝑉_𝑂𝑈𝑇=60𝑉)

Mosfet Losses Diode Loss Capacitor Loss Inductor Loss
Inductor Loss Mosfet Losses

24% 19%
Capacitor Loss
3%
Diode Loss
54%
Now, comparing these data with the PLECS Simulation done for the Nominal Operating Point:-
Fig:- Open Loop Simulation in PLECS.

However, the display figures are not readable here, in the attached PLECS files, the simulation
performed can show the reader the exact values achieved and can compare with the designed
values.
Below are the Voltage and Current Plots for each winding along with its ripple
characteristics in a magnified view:-
41 | P a g e
Output Voltage Plot:-
Fig:- Output Voltage Plot
Output Voltage (Ripple Magnified):-
Fig:- Output Voltage (Ripple Magnified ) Plot
42 | P a g e
Output Current (Ripple Magnified):-
Fig:- Output Current (Ripple Magnified) Plot
Inductor Voltage (Ripple Magnified):-
Fig:- Inductor Voltage (Ripple Magnified)
43 | P a g e
Efficiency Plot for the Variation of the Load when the converter operates at Nominal Point:-
Fig:- Efficiency Plot for the Variation of Load for Nominal Operating Point.
5.1.1 (B)Operation at Vin= 70 Volt, Vout = 60 Volt:-

Mosfet Losses
Inductor Loss 17%
25%
Capacitor Loss
3%
Diode Loss
55%
Fig:- Loss Distribution
44 | P a g e
Now, comparing these data with the PLECS Simulation done for this Operating Point:-
Fig:- Open Loop Simulation for the corresponding Operating Point in PLECS
Next are the Voltage Plots:-
Fig:- Output Voltage Plot. (Figures aren’t clear, refer to the attached files)
45 | P a g e
Fig:-Output Voltage (Ripple Magnified) Plot

Output Current (Ripple Magnified):-
Fig:- Output Current (Ripple Magnified)
46 | P a g e
Inductor Voltage:-
Fig:- Inductor Voltage (Values are not clear, Refer to the attachment)
47 | P a g e
Inductor Current (Ripple Magnified):-
Fig:- Inductor Current (Ripple Magnified)

Efficiency Plot for the Variation of the Load in the operating Point:-
Fig:- Variation of the Load w.r.t to operating Point
48 | P a g e
5.1.1 (C)Operation at Vin= 70 Volt, Vout = 50 Volt:-

Mosfet Losses
Inductor Loss 17%
25%
Capacitor Loss
2%
Diode Loss
56%

Fig:- Open Loop Simulation in PLECS.

49 | P a g e
Output Voltage Plot:-
Fig:- Output Voltage Plot (values are not readable, refer the attachment)
Fig:- Output Voltage (Ripple Magnified)
50 | P a g e
Inductor Voltage:-
Fig:- Inductor Voltage (values are not readable, refer to the attachment)
51 | P a g e

Efficiency Plot for Variation of the Load wr.t Operating Point:-
Fig:- Variation of the Load w.r.t Operating Point
52 | P a g e
5.2 Step-Up Mode :-

5.2.1 Loss Distribution data in the Step-Up Mode:-
The loss distribution in the Step-Up Mode is depicted via three different operating point
Simulations.
Step-Up Mode 80 Volts 100 Volts
60 Volts 100 Volts
60 Volts 80 Volts
The Losses calculated in all the 3 different operating modes are:-
Losses (Watts) 𝑉𝐼𝑁 = 80𝑉 & 𝑉𝑂𝑈𝑇 = 100𝑉 𝑉𝐼𝑁 = 60𝑉 & 𝑉𝑂𝑈𝑇 = 100𝑉 𝑉𝐼𝑁 = 60𝑉 & 𝑉𝑂𝑈𝑇 = 80𝑉
Mosfet Loss 28.295 Watts 22.61 Watts 27.704 Watts
(SW + Cond)
Diode Loss 36.99 Watts 36.99 Watts 46.25 Watts
(Conduction)
Capacitor Loss 1.062 Watts 1.062 Watts 1.062 Watts
(Conduction)
Inductor 4.50 Watts 4.50 Watts 7.03 Watts
(Magnetic +
Copper)
Transformer 36.716 Watts 94.136 Watts 76.716 Watts

(Magnetic Core
and Copper
Losses)
Total Losses 107.563 Watts 159.29 Watts 158.76 Watts
Table :- Loss Distribution in Step-Up Mode
53 | P a g e
5.2.1 (A)Operation at the Nominal Operating Point:-

Input Voltage = 80 Volts ; Output Voltage = 100 Volts
LOSSES IN HALF-BRIDGE(NOMINAL OPERATING

POINT)
Switching Loss Magnetic Core Loss Conduction Loss
Switching Loss
25%
Conduction Loss
41%
Magnetic Core
Loss
34%
Fig:- Losses in Step-Up Mode (Nominal Operating Point)

Conduction Losses Distribution are:-

Mosfet S1,2 &3 Diode D5 Rectifier Diodes Inductor Capacitor (C3 &C4)
1.062 1.295
0
4.5
36.99
Fig:- Conduction Losses in Step-Up Mode
54 | P a g e
LOSSES IN HALF BRIDGE (𝑉_𝐼𝑁=80𝑉 &

𝑉_𝑂𝑈𝑇=100𝑉)
Mosfet Losses Diode Loss Capacitor Loss Inductor Loss Transformer Losses
Transformer Mosfet Losses

Losses 26%
34%
Inductor Loss
Capacitor Loss Diode Loss
4%
1% 35%
Fig:- Losses at the Nominal Operating Point
Now, comparing these data with the PLECS Simulation done for this Operating
Point:-
Fig:- Open-Loop Simulation in PLECS
55 | P a g e

Output Voltage:-

Fig:- Output Voltage(Ripple Magnified)
56 | P a g e
Inductor Voltage:-
Fig:- Inductor Voltage (Here the direction of the Voltmeter places is opposite)
Fig:- Inductor Voltage ( Ripple Magnified)
57 | P a g e
Secondary Voltage (Ripple Magnified):-
Fig:- Secondary Voltage Ripple Magnified

Capacitor Voltage (Ripple Magnified) :-
Fig:- Capacitor Voltage (Ripple Magnified)
58 | P a g e
Capacitor Voltage (C1):-
Fig:- Capacitor Voltage

Secondary Voltage:-
Fig:- Secondary Voltage
59 | P a g e
Efficiency Plot for Variation of Load:-
5.2.1 (B)Operation at Vin= 60 Volt, Vout = 100 Volt:-
LOSSES IN HALF BRIDGE (𝑉_𝐼𝑁=60𝑉 & 𝑉_𝑂𝑈𝑇=100𝑉)

Mosfet Losses
14%
Diode Loss
Transformer Losses 23%
59%
Capacitor
Inductor Loss
Loss
1%
3%
60 | P a g e
Fig:- Open Loop Simulation in PLECS

Output Voltage:-
Fig:- Output Voltage (values are not clear, refer to the attachment below)
61 | P a g e

Inductor Voltage:-
Fig:- Inductor Voltage
62 | P a g e

Capacitor Voltage:-
63 | P a g e
Capacitor Voltage (Ripple Magnified):-

Secondary Voltage:-
64 | P a g e
Fig:- Secondary Voltage (Ripple Magnified)

65 | P a g e
Efficiency Variation of the Load w.r.t Operating Point:-
5.2.1 (C)Operation at Vin= 60 Volt, Vout = 80 Volt:-
LOSSES IN HALF BRIDGE (𝑉_𝐼𝑁=60𝑉 &

Mosfet Losses
18%
Transformer
Losses
48%
Diode Loss
29%
Inductor
Capacitor
Loss Loss
4% 1%
66 | P a g e
Fig:- Open Loop Simulation in PLECS

Output Voltage:-
Fig:- Output Voltage
67 | P a g e

Inductor Voltage:-
Fig:- Inductor Voltage
68 | P a g e

69 | P a g e
Capacitor Voltage:-

Capacitor Voltage (Ripple Magnified):-
70 | P a g e
Secondary Voltage:-

Fig:- Secondary Voltage (Ripple Magnified)
71 | P a g e
Efficiency Plot for the Variation of the Load:-
5.3 Equal Mode :-

5.3.1 Loss Distribution data in the Equal Mode:-
The loss distribution in the Equal Mode is depicted via three different operating point
Simulations.
Equal Mode 80 Volts 80 Volts
Losses (Watts) 𝑉𝐼𝑁 = 80𝑉 & 𝑉𝑂𝑈𝑇 = 80𝑉

Mosfet Loss 0.976 Watts
(SW + Cond)
Diode Loss 46.25 Watts
(Conduction)
Capacitor Loss 0.9804 Watts
(Conduction)
Inductor 7.03 Watts
(Magnetic + Copper)
Total Losses 55.23 Watts
72 | P a g e
LOSSES IN EQUAL MODE(NOMINAL OPERATING

POINT)
0
Switching Loss
Magnetic Core Loss
Conduction Loss
47.2318
Fig:- Losses Distribution in Equal Mode

Conduction Loss Distribution:-

Mosfet S3 Diode D5 Rectifier Diodes Inductor Capacitor (C3 &C4)
0.98182 0.976 0
7.03
46.25
73 | P a g e
LOSSES IN EQUAL MODE (𝑉_𝐼𝑁=80𝑉 &

Inductor Loss, Mosfet Losses,
12% 2%
Capacitor Loss,
2%
Diode Loss, 84%
Fig:- Losses in Equal Mode (Nominal Operating Point)

Fig:- Open Loop Simulation In PLECS
Next are the Voltages:-
74 | P a g e
Output Voltage:-

Output Current:-
Fig:- Output Current Plot
75 | P a g e
Inductor Current:-
Fig:- Inductor Current Plot
Inductor Voltage:-
Fig:- Inductor Voltage Plot
Here the Inductor Voltage is 0 volts, as the difference between the input and output voltage is zero. Thus
there is no voltage across the Inductor.
76 | P a g e
Efficiency Variation w.r.t nominal Operating Point:-
77 | P a g e
CONCLUSION:-
While designing the converter, there were some design trade-off required to be taken
in order to achieve the desired Specification. The Mosfet Switch S3 , was in
continuous conduction in the Equal and Step-Up Mode. Thus, while selecting the
component, the least possible value of the Mosfet On-resistance was required.
However, while selecting the component of 1 Milli Ohm, the voltage rating and the
current rating were high. This increases the economics of the Converter Design. The
Switching Loss in the Diodes were neglected due to the unavailability of the reverse
recovery parameters. However, we have neglected sufficient amount of losses
through this assumption. Thus, the converter designed will operate at lower
efficiency with these losses included. In designing the Inductor, in order to limit the
Magnetic Core loss, the design constraints had to meet the lowest Kg value possible.
For this the value of the Inductor had to be decreased. Thus, the only way to achieve
that was either increasing the series resistance across the Inductor or by increasing
the Switching Frequency. As the Switching frequency didn’t depend on any of the
loss calculations in the Inductor, it was a calculated approach to increase the
Switching Frequency. Thus, the choice of increasing the Frequency from 100Khz to
450Khz was undertaken. Although, this increased the switching loss in the Mosfet
by a fraction, but the Inductor was designed at the cost of lower Magnetic Losses.
In designing the Transformer, in order to operate the Step-Up mode at efficient
operation, the number of turns in the transformer winding had to be increased. This
is because in order to allocate sufficient amount of losses in the Transformer core.
Thus, in increasing the number of turns in the transformer, made the copper losses
in the transformer shoot up, but overall also made the converter more efficient. This
trade-off of more losses for better realistic efficiency was to justify the fact that the
Step-down mode in this converter design operates at higher efficiency than the Step-
Up Mode.
78 | P a g e
References:-
[1] Erickson Textbook:-
https://eleccompengineering.files.wordpress.com/2015/01/fundamentals-of-power-
electronics_2nd_erickson_full.pdf
[2] IEEE Reference Paper:-
Q. Du, B. Qi, T. Wang, T. Zhang and X. Li, "A High-Power Input-Parallel Output-Series Buck
and Half-Bridge Converter and Control Methods," in IEEE Transactions on Power Electronics,
vol. 27, no. 6, pp. 2703-2715, June 2012.
URL: http://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=6096436&isnumber=6170969
[3] Component Selection Website:-
http://www.mouser.com
http://www.digikey.com
[4] Switching Loss for Mosfet Reference:-
http://application-notes.digchip.com/070/70-41484.pdf
[5] Capacitor ESR Equation reference:-
https://forum.digikey.com/t/calculating-capacitor-esr-from-tan/2633
[6] Buck Inductor Reference theory:-

https://www.digikey.com/
79 | P a g e
Appendix:-
1) MOSFET S1, S2, S3 Datasheet:- (FINAL DESIGN)
https://www.digikey.com/product-detail/en/ixys/IXTN400N15X4/IXTN400N15X4-
ND/10222206
2) MOSFET S1, S2, S3 Datasheet:- (PRELIMINARY DESIGN)
https://www.digikey.com/product-detail/en/infineon-
technologies/IPT059N15N3ATMA1/IPT059N15N3ATMA1CT-ND/4571880
https://www.datasheets360.com/part/detail/ipb036n12n3g/7002674457431775820/
(NOTE:- This component datasheet above was initially selected from Mouser website, but the
link crashed in word, thus cited from different website)
3) Diode D1,D2,D3,D4,D5 Datasheet (FINAL DESIGN)
https://www.digikey.com/product-detail/en/smc-diode-
solutions/129SPC150A/129SPC150ASMC-ND/5992346
4) Diode D1,D2,D3,D4,D5 Datasheet (PRELIMINARY DESIGN)
https://www.mouser.com/Semiconductors/Discrete-Semiconductors/Diodes-
Rectifiers/Schottky-Diodes-Rectifiers/Datasheets/_/N-ax1mj?keyword=APT60S20B
5) Capacitor C1,C2,C3 Datasheet (Final Design)
https://www.digikey.be/product-detail/en/epcos-tdk/B43501A3107M000/B43501A3107M000-
ND/3496250
6) Capacitor C1, C2, C3 Datasheet (Preliminary Design)
https://www.digikey.com/product-detail/en/epcos-tdk/B41890A5108M000/495-6061-
ND/3494557
7) Capacitor C4 (Final Design)
https://www.digikey.co.nz/product-detail/en/out-of-bounds/TE1500-E3/TE1500-E3-
ND/5612733
8) Capacitor C4 (Preliminary Design)
https://www.digikey.com/product-detail/en/nichicon/UVR2AR22MDD/493-1137-ND/588878
80 | P a g e
MATLAB Script for Efficiency and Losses Calculation in Buck Mode:-

clc;
clear all;
efficiency=[]
efficiencyR = []
% MATLAB Code for Losses Calculation in Buck Mode
%
%Definition of parameters
V_in=[80 70 70];
V_out = [60 60 50];
b=1;
for b=1:3
Vin= V_in(1,b);
Vout = V_out(1,b);
Pout = 250;
p=1;
while Pout<= 2500
D = Vout/Vin;
Ron= 1*10^-3;
Rl = 0.0072;
fsw = 450000;
L = 50*10^-6;
Ioutmax = 50;
Imax = Ioutmax*sqrt(1 + (((0.5/Ioutmax)^2)/3));
disp(Imax);
Il = Pout/Vout;
D1 = 1-D;
Vd = 0.74;
irr = 0;
trr = 0 *10^-9;
Qrr = 0 *10^-9;
Vd_rect = 0.74;
irr_rect = 0;
trr_rect = 0 *10^-9;
Qrr_rect = 0*10^-9;
ESR1 = 1.41*10^-3;
ESR2 = 1.02;
deltai = 1;
trise = 22*10^-9;
tfall = 8*10^-9;
Kfe = 24;
Bmax =0.2;
delB_inductor= 0.005;
81 | P a g e
beta =2.7;
Ac =3.24;
Wa = 6.75;
MLT = 14;
lm = 18;
Ku = 0.6;
rho = 1.724*10^-6;
%%
%Loss Calculation
Kg = (rho * (L^2) * (Imax^2) * 10^8)/((Bmax^2)*Rl*Ku);
lg = ((4*pi*10^-7)*L*Imax^2)/((Bmax^2)*Ac);
n = (L*Imax*10000)/(Bmax*Ac);
Aw = (Ku*Wa)/n;
Rl_calc = (rho*n*MLT)/Aw;
Pcond_ind = (Il^2)*(Rl)
Pcond_mosfet = (Il^2)*(D*Ron)
Pcond_diode_buck = Il*(D1*Vd)
Pcond_diode_rect = Il*(2*Vd_rect)
Pcond_C1= ((deltai^2)*(ESR1))
Pcond_C2= ((deltai^2)*ESR2)
Pcond = Pcond_ind + Pcond_mosfet + Pcond_diode_buck + Pcond_diode_rect + Pcond_C1 +
Pcond_C2
Psw_mosfet = fsw*(Vin *Il*((trise + tfall)/2))

Psw_diode = ((Vin * Il* trr) + (Vin*Qrr))*fsw
Psw = Psw_mosfet + Psw_diode
Pmag = Kfe*(delB_inductor^beta) * Ac * lm
Ploss_total = Pcond +Psw + Pmag
Eff = (Pout/(Pout+Ploss_total))*100
Eff_1 = (Pout/(Pout+Ploss_total))*100
%efficiency=[];
efficiencyR(b,p) = Eff;
efficiency(b,1) = Eff_1;
Pout = Pout + 250 ;
p=p+1;
end
end
figure(1)
plot(efficiencyR(1,:),'r-','LineWidth',5)
grid
82 | P a g e
axis([0 10 0 100])
title('Efficiency Plot for Vin=80 & Vout=60')
xlabel('Variation from light load to full load')
ylabel('Efficiency')
figure(2)
plot(efficiencyR(2,:),'k-','LineWidth',5)
grid
axis([0 10 0 100])
figure(3)
plot(efficiencyR(3,:),'LineWidth',5)
grid
axis([0 10 0 100])
figure (4)
array = [ 1,2,3]
plot(efficiency,'b','LineWidth',5)
grid
axis ([1 4 0 100])
title('Efficiency Plot for 3 given operating points')
MATLAB Script for Efficiency and Losses Calculation in Half-Bridge Mode:-

clc;
clear;
efficiency=[]
efficiencyR = []
V_in=[80 60 60];
V_out = [100 100 80];
b=1;
for b=1:3
Vin= V_in(1,b);
Vout = V_out(1,b);
Pout = 250;
p=1;
while Pout<= 2500
Iout = Pout/Vout;
Ron = 1*10^-3;
Rl = 0.0072;
Vf = 0.74;
83 | P a g e
n= 2;
Dhb_loss= (Vin-Vout-(Iout*Ron)-(Iout*Rl)-(2*Vf))/((-n*Vin)+(2*(n^2)*Iout*Ron))
Dhb1_loss = 1-2*Dhb_loss;
fsw = 450000;
ESR1 = 1.4*10^-3;
ESR2 = 1.02;
trise = 22*10^-9;
tfall = 8*10^-9;
Irms_s= Iout*sqrt(Dhb_loss)*sqrt(1+((0.33)*((1./Iout)^2)))
Itot= Irms_s*4;
rho = 1.724*10^-6;
Ku = 0.6;
MLT= 2.30;
Kfe =24;
Wa = 0.055;
deltai= 1;
lambda1 = 2.45*10^-5;
delB = 0.11;
delB_inductor = 0.005;
Ac = 0.167;
Bmax = 0.2;
beta = 2.7;
Ac_ind = 3.24;
lm_ind = 18;
Ac_x = 0.167;
lm_x = 1.55;
%%
%n1 = (lambda1*10^4)/(2*delB*Ac)
n1=15;
Pcopper = (rho*MLT*(n1^2)*(Itot^2))/(Wa*Ku)
Psw_Mosfet12= 2*(Vin*n*Iout*fsw*((trise+tfall)/4))
Pcond_Mosfet3 = (Iout^2)*Ron
Pcond_ind = (Iout^2)*Rl
84 | P a g e
Pcond_Mosfet = 2*(((n*Iout)^2)*Ron)*Dhb_loss
Pcond_diode13 = 4*Dhb_loss*Vf*Iout
Pcond_diode24 = 4*Dhb1_loss*Vf*(Iout/2)
Pcond_C1= 3*((deltai^2)*(ESR1))
Pmag_ind = Kfe*(delB_inductor^beta) * Ac_ind * lm_ind

Pmag_x = Kfe*(delB^beta) * Ac_x * lm_x
Ploss_total = Pcond_C1 + Pcond_C2+ Pcond_diode24+ Pcond_diode13 +Pcond_Mosfet

+Pcond_ind +Pcond_Mosfet3 +Psw_Mosfet12 +Pcopper +Pmag_ind + Pmag_x
Eff = Pout*100/(Pout+Ploss_total)
%efficiency=[];
Pout = Pout + 250 ;
p=p+1;
end
end
figure(1)
grid
axis([0 10 0 100])
figure(2)
plot(efficiencyR(2,:),'k-','LineWidth',5)
grid
axis([0 10 0 100])
figure(3)
plot(efficiencyR(3,:),'LineWidth',5)
grid
axis([0 10 0 100])
figure (4)
array = [ 1,2,3]
plot(efficiency,'b','LineWidth',5)
85 | P a g e
grid
axis ([1 4 0 100])
title('Efficiency Plot for 3 given operating points')
MATLAB Script for Efficiency and Losses Calculation in Equal Mode:-

clc
clear all;
efficiency=[]
efficiencyR = []
% MATLAB Code for calculation of losses
%
%Definition of parameters
V_in=[80];
V_out = [80];
b=1;
for b=1:1
Vin= V_in(1,b);
Vout = V_out(1,b);
Pout = 250;
p=1;
while Pout<= 2500
D = Vout/Vin;
Ron= 1*10^-3;
Rl = 0.0072;
fsw = 450000;
L = 50*10^-6;
Ioutmax = 50;
Imax = Ioutmax*sqrt(1 + (((0.5/Ioutmax)^2)/3));
disp(Imax);
Il = Pout/Vout;
D1 = 1-D;
Vd = 0.74;
irr = 0;
trr = 0 *10^-9;
Qrr = 0 *10^-9;
Vd_rect = 0.74;
irr_rect = 0;
trr_rect = 0 *10^-9;
Qrr_rect = 0*10^-9;
ESR1 = 1.41*10^-3;
ESR2 = 1.02;
deltai = 1;
trise = 22*10^-9;
86 | P a g e
tfall = 8*10^-9;
Kfe = 24;
Bmax =0.2;
delB_inductor= 0.005;
beta =2.7;
Ac =3.24;
Wa = 6.75;
MLT = 14;
lm = 18;
Ku = 0.6;
rho = 1.724*10^-6;
%%
%Loss Calculation
Kg = (rho * (L^2) * (Imax^2) * 10^8)/((Bmax^2)*Rl*Ku);
lg = ((4*pi*10^-7)*L*Imax^2)/((Bmax^2)*Ac);
n = (L*Imax*10000)/(Bmax*Ac);
Aw = (Ku*Wa)/n;
Rl_calc = (rho*n*MLT)/Aw;
Pcond_ind = (Il^2)*(Rl)
Pcond_mosfet = (Il^2)*(D*Ron)
Pcond_diode_buck = Il*(D1*Vd)
Pcond_diode_rect = Il*(2*Vd_rect)
Pcond_C1= ((deltai^2)*(ESR1))
Pcond = Pcond_ind + Pcond_mosfet + Pcond_diode_buck + Pcond_diode_rect + Pcond_C1 +
Pcond_C2
Psw_mosfet = fsw*(Vin *Il*((trise + tfall)/2))

Psw_diode = ((Vin * Il* trr) + (Vin*Qrr))*fsw
Psw = Psw_mosfet + Psw_diode
Pmag = Kfe*(delB_inductor^beta) * Ac * lm
Ploss_total = Pcond +Psw + Pmag
%efficiency=[];
Pout = Pout + 250 ;
p=p+1;
end
87 | P a g e
end
figure(1)
grid
axis([0 10 0 100])
88 | P a g e
89 | P a g e

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ECE 534 Project Part 1 Jay Praful Chheda

NORTH CAROLINA STATE UNIVERSITY

DESIGN & IMPLEMENTATION OF INPUT-PARALLEL OUTPUT-

JAY PRAFUL CHHEDA Dr .SUBHASHISH BHATTACHARYA

NOVEMBER 17, 2019

Abstract :- (Project Summary)

Table No Table Title Page No

1. Selection of the MOSFET 11

2. Selection of the Diode 13

3. Transformer Core Design Parameters 18

4. Excel Sheet for Transformer Design Calculation 20

5. Design Constraint Parameters 20

6. Design Constraint for Flux Density 21

7. Design Parameters Achieved for Primary Winding Turns 21

8. Design Parameters Achieved for Primary Winding Wire Size 22

9. Design Parameters Achieved for Secondary Wire Size 23

10. Inductor Design Parameters 25

11. Design Parameters Calculated for Air-Gap Length 26

12. Design Parameters Calculated for Number of Turns 26

13. Design Parameters of the Selected Core(EE70) 27

14. Comparison of Iterations of Inductor 29

15. Selection of the Input Capacitor 30

16. Selection of the Output Capacitor 31

17. Given 3 Operating Points for Buck Mode 32

18. Achieved results for losses in the Buck Mode 32

19. Given 3 Operating Points for Step-Up Mode 46

20 Achieved Results for Losses in the Step-Up Mode 46

21 Given 3 Operating Points for Equal Mode 65

22 Achieved results for losses in the Equal Mode 65

Figure No Figure Title Page No

1 Buck Module Circuit (Simulated in PLECS) 5

2 Buck Module Sub-Circuit1 (Simulated in PLECS) 6

3 Buck Module Sub-Circuit 2(Simulated in PLECS) 6

4 Buck Inductor Current Waveform 8

5 Buck Capacitor Voltage Waveform 8

6 Buck Converter Considering The Losses. 9

7 Half Bridge Module Sub-Circuit 2&4 (Simulated in PLECS) 10

8 Half Bridge Module Sub-Circuit 2&4 (Simulated in PLECS) 12

9 Equal Mode (Simulated in PLECS) 14

10 Average Inductor Current Waveform 15

11 𝐾𝑔𝑓𝑒 design Constraint 17

12 Rms Current Waveform (Transformer) 18

13 Flux Density Constraint of the Selected Core 19

14 Evaluation of Primary Winding Turns 20

15 Evaluation of Secondary Turns 22

16 Evaluation of Primary Winding Wire Size 22

17 Evaluation of Secondary Wire Size 23

18 Evaluation of Magnetic Winding Inductance 23

19 Evaluation of Magnetic Peak Current 23

20 Evaluation of Winding Resistance 23

21 Evaluation of Magnetic Core Loss 24

22 Evaluation of Magnetic Copper Loss 24

23 Evaluation to determine the Core Constraints 25

24 Evaluation to determine Air-Gap Length 25

25 Equation for Evaluation of number of turns 26

26 Equation to determine the Wire Size of Inductor Winding 26

27 Final Comparison of Projected and Designed value of Inductor Series 26

28 Efficiency Plot for 3 different Operating Points combined 32

29 Losses in the Buck Mode 33

30 Open Loop Simulation in PLECS 34

31 Output Voltage Plot 35

32 Output Voltage (Ripple Magnified) Plot 35

33 Output Current (Ripple Magnified) Plot 36

34 Inductor Voltage (Ripple Magnified) 36