ECE 534 Fall 2019

Project Part-1
(Due Date: November 10, 2019 at 11:55 pm)

Description
Implementation of two DC-DC converters operating in series or parallel is the most
frequently used solution for efficient high power applications. Operating the converters in
such an arrangement generally gives higher reliability, higher efficiency and greater margin
for stability of the converter over wide range of input voltages and output power. One of
such arrangements discussed in IEEE Transactions on Power Electronics is – ‘Input-Parallel
Output-Series Buck and Half-Bridge Converter’ (IPOSBHB) Converter.[1]
In this project assignment, students will be tasked with the “complete” design of the
IPOSBHB Converter in Continuous Conduction Mode (CCM). This design should include
the closed loop design of the converter with implementation of compensator to regulate the
performance of the converter. The circuit structure of the converter looks as follows:

Figure 1: IPOSBHB Converter

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Design Specification

The desired converter specifications are enlisted in table below. Adhere to these specifi-
cations for selecting components for designing IPOSBHB Converter.

Input Voltage Range 20 - 80 V

Output Voltage Range 50 - 100 V
Output Power 2.5 kW
Maximum output current ripple (peak-peak) 1A
Maximum output voltage ripple (peak-peak) 2V
Minimum efficiency in Step-Down Mode 95%
Minimum efficiency in Step-Up Mode 90%
Minimum efficiency in Equal Mode 98%
Switching Frequency >50 kHz
Operating Temperature 0◦ C-45◦ C

Operating Principle of Converter

The converter can operate in three different modes depending upon the input voltage
and required output voltage. The three different modes are stated below:

1. Step-Down Mode When input voltage is higher than the desired output voltage, in
that case the whole input power is transferred through the Buck Module.

2. Step-Up Mode In this scenario, S3 switch is always on so that the output voltage of
the converter can be equivalent to the input voltage in series with the output voltage
of half-bridge circuit.

3. Equal Mode No switching action will be performed. S3 will be always on and S1 and
S2 are always off. Basically, Vin = Vo .

Project Part-1 Tasks

1. Design the converter

Provide the steady state analysis of the given converter. The input as well as output
voltage of the converter has an operating range. Assume the nominal operating points
for the three modes as follows:

(a) Step-Down Mode

Vin = 80V; Vo = 60V
(b) Step-Up Mode
Vin = 80V; Vo = 100V
(c) Step-Down Mode
Vin = 80V; Vo = 80V

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 Based on the nominal operating points, carry out further calculations mentioned below.
Part 1 of the project only focuses on the open loop design of the IPOSBHB converter
at the steady state.

2. Selection of Power Switches and Diodes

For the power switch selection, you need to come up with the rated blocking voltage
and rated rms and peak current of the switch. Since the switching frequency is high, a
Power MOSFET is preferred so that the switching losses are kept within limits. Here,
the RDS(on) of the MOSFET becomes important since it will determine the conduction
loss which is the major loss contribution of MOSFET. For the diode selection, you
need to calculate the rated blocking voltage and average forward current of the diode.
In selecting the power switch and diode, always consider a safety margin of at least
1.5. Based on your semiconductor selection, calculate the loss components associated
with each semiconductor device and check them with your efficiency condition.

3. Design of Transformer and Inductor

Design the high frequency transformer of the half bridge converter based on kgfe
method or any other suitable design method. Use Ferrite material N87 with maxi-
mum flux density Bmax =0.2T as the core material for the transformer. Show the core
losses and copper losses for the designed transformer. Use the datasheet from: N87
Ferrite properties to find the core loss parameters (at 100◦ C) for N87 material. You
need to do detailed transformer design and show all the steps with all design param-
eters and values. Take Ku =0.6, Bmax =0.2 T. Select core from the list of cores from
here. Credits will be given for smaller size and weight. Alternatively, you can design
the transformer using cores given in Appendix D of Erickson’s textbook. You can use
β = 2.7 and Kf e = 24 W/Tβ cm3 .
Design the inductor of the buck converter unit based on the ripple current limit given
in the specification table.

4. Selection of Capacitors

The capacitor selection should be done based on output voltage ripple requirements.
After you have determined the rated voltage (including some 1.5 safety margin) and
required capacitance, choose the output capacitor. You should consider the ESR
(Equivalent Series Resistance) of capacitors at the corresponding switching frequency.
This series equivalent resistance times the ripple current passing through the capacitor
causes an extra output voltage switching ripples and also leads to capacitor heat-up
and life cycle decrease. You should choose a capacitor with a low ESR such that the
output ripple requirement is satisfied at the switching frequency. Having the output
capacitor RMS currents and their ESRs, you can also calculate the power loss in out-
put capacitors. This is important with respect to capacitor heat-up and efficiency
requirements.

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 5. Calculation of Losses and Efficiencies

Calculate for efficiency determined by selection of switches, power diodes, ESR of the
output capacitance, inductor losses and transformer losses at different operating points
for each mode of operation including the selected nominal operating point. Construct
the actual power loss distribution of the converter and calculate light load and rated
load efficiencies. For efficiency calculations, please consider load from 10% of rated
load to 100% of rated load in steps of 10% i.e. 10%, 20%, 30% and so on till 100%.

6. Simulate the open loop model in PLECS

Simulate your design and demonstrate different characteristics at light load and rated
load. Carry out the thermal modeling of the power switches in PLECS. Extra credits
will be awarded for carrying out magnetics modeling for transformer and inductor in
PLECS. Calculate the efficiencies at different operating condition from PLECS chosen
in step 5.

Project Deliverables

You are required to turn in a design report in PDF format alongwith PLECS file in a
zipped on the due date uploaded to the course website on the Moodle submissions page. To
help in project grading, please name the files as specified below

1. Report as unityid Rep Lastname firstname.pdf

2. PLECS files (each for thet three modes) as unityid Sim mode Lastname firstname.pdf

3. Zipped folder as (unityid Proj Lastname firstname.pdf).

The report must contain the following:

(A) Title page with project name, your names, date, and an academic integrity statement.

(B) A single paragraph executive summary.

(C) A compliance table summarizing the simulated nominal performance of your circuit
versus the specifications. This table should list the design requirements and then list
your achieved results. Any specifications not met should be highlighted in red text.

(D) Technical discussion of your design, explaining design of the Converter.

(E) Design is an iterative process. You may have to design multiple times to meet the
specifications. Please submit 2 designs :

(a) Preliminary Design

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 (b) Final Design
All datasheets need to be submitted as Appendix for final design only. For pre-
liminary design, please submit the type number of component selected along with
Digikey/Mouser link as part of appendix.

(F) Conclusion with comments of what changes would enhance the performance of your
design. If some performance values do not meet specification then add clear discussion
in the report as to what aspects of your design are limiting the performance and the
trade-offs you made.

(G) Clear and legible plots (zoomed) and graphs for following :

(a) Output voltage for each winding.

(b) Magnified view of output voltage with ripple
(c) Efficiency curve for whole range of D ( from 0 to 1)
(d) Schematics with component values. Component values can be shown in PLECS.
(e) Pie chart with loss distribution for different operating points as well as light and
rated loading.

(H) Cite references in your report if you use any ideas from other sources (IEEE Papers,
conferences, etc.)

Academic Integrity

Please note that it is an individual project. The design and reports must represent student’s
own original work. Absolutely no sharing of schematics, designs, plots and write-ups will
be accepted. Students in violation of this policy will be reported to the NCSU Office of
Student Conduct, with repercussions including placement on academic probation and grade
penalties including but not limited to receiving a zero on the design project. Please refer to
the NCSU Academic Integrity Policy (see syllabus) as well as the office of student conduct
for the NCSU policies.

Useful Links

1. http://www.mouser.com

2. http://www.digikey.com

Grading Rubric

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 S.No. Grading Component Marks
1. Report Write-up 20
2. Plecs File and performance as per specification 40
3. Plots and graphs as per section 9(g) 10
4. Summary of all component ratings used and data sheets for all 10
components for final design (Put data sheets in Appendix section
at the end of report)
5. Analytical thermal analysis, calculation of switching and conduc- 10
tion losses
6. Thermal simulation, simulation of switching and conduction 10
losses
7. Magnetic simulation (Extra Credits) 10
8. Transformer sizing (Extra Credits) 5

References
[1] 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.