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A Single-Stage Single-Switch Soft-Switching (S6) Boost-Flyback PFC Converter
A Single-Stage Single-Switch Soft-Switching (S6) Boost-Flyback PFC Converter
Abstract—This paper presents a single-stage single-switch soft- such as LED drivers [2], [6], ballast circuits [7], [8], and battery
switching (S6) power factor correction (PFC) converter to enhance chargers [9], [10].
the current shaping performance and reduce the total harmonic These converters operate under either continuous conduction
distortion. This improvement is achieved by the aid of an auxiliary mode (CCM) or discontinuous conduction mode (DCM) [11],
winding which is used to lower the input current harmonics and
also achieve soft-switching condition. As a result, the switching
[12]. Operating the converter under DCM allows the input in-
losses are reduced and harmonic content of the input current is ductor current to depend only on the input voltage and not on
improved noticeably in comparison to the conventional S6 PFC the previous cycle parameters which can eliminate the current
converter. Also, the total number of semiconductor elements is control loop of current shaping stage and simplify the control
reduced in the proposed topology which results in lower cost and circuit and also, make it possible for the dc–dc stage to achieve
higher efficiency. The operating modes of the proposed converter fast output regulation. On the other hand, operating under CCM
are discussed in detail and the design procedure is presented. A condition produces less high-order harmonics that means higher
200-kHz prototype of the proposed converter is implemented and efficiency is possible in CCM [12]. In the proposed topology,
the obtained results are provided to verify the converter theoretical
analysis and operation.
the DCM operation is selected due to self-PFC characteristic
and also other desired features which are discussed.
Index Terms—AC–DC converter, dc–dc converter, power factor Soft switching methods are applied to single-stage PFC con-
correction (PFC), single-stage, soft switching. verters to improve the efficiency and further increase the oper-
ating switching frequency [13]–[22]. However, soft-switching
I. INTRODUCTION characteristic in these converters is mostly achieved by using
N RECENT years, power conversion equipments connected additional switches and other circuit components which results
I to the grid are constantly increasing. In order to manage
the problems associated with the harmonic pollution of power
in more complicated control scheme and extra cost [14]–[18]. In
addition to these drawbacks, the loss associated with the newly
added circuit is another concern in such methods. Neverthe-
conversion equipment and fulfil the harmonic current limits set
by standards like IEC61000-3-2 [1], it is imperative to develop less, some of these PFC converters like boost flyback converters
power-factor correction (PFC) techniques [2]–[4]. Thus, major proposed in [16], [17] are not capable of achieving full soft
research has been carried out to address the aforementioned switching condition.
issues and develop high-performance PFC converters [2]–[10]. In order to overcome the above-mentioned shortcomings, the
Two-stage cascade PFC converter which consists of a PFC idea of single stage-single switch-soft switching (S6) PFC con-
stage and dc–dc stage is an approach to achieve a smooth output verters are developed [13], [19]–[22] which achieve soft switch-
voltage in conjunction with a high power factor. By using sepa- ing condition without any extra switch and only by adding few
rate controllers, these converters can achieve high performance passive components and/or extra diodes. An integrated SEPIC-
input current shaping and output voltage regulation. However, flyback PFC converter is proposed in [19] as an LED driver.
the major drawback of this type of PFC is its high cost due to However the converter only achieves soft-switching at turn-ON.
high device count (of at least two switches and a separate con- S6 LED drivers proposed in [20] and [21] are capable of achiev-
troller for each stage) [3]. In order to overcome this problem, ing low total harmonic distortion (THD) but they have high num-
single-stage PFC converters are developed in which the current ber of components. Moreover, they do not achieve soft switching
shaping and the dc–dc stages are combined [3]–[10]. In most condition at switch turn OFFwhich degrades their efficiency. In
single stage structures, the dc–dc stage switch, together with [22] a single-stage isolated power-factor-corrected power sup-
other elements, act as the current shaping stage. Single stage ply is introduced which uses a regenerative clamping to reduce
PFC converters are commonly used in low-power applications, the voltage stress and to recycle the energy trapped in the leak-
age inductance. However, same as [20] and [21] it suffers from
high number of semiconductor components and not achieving
Manuscript received July 13, 2018; revised October 3, 2018 and December soft-switching condition at turn-OFF.
1, 2018; accepted January 18, 2019. Date of publication January 24, 2019; date In [13], a boost flyback S6 PFC converter is proposed in which
of current version June 28, 2019. Recommended for publication by Associate
Editor M. Duffy. (Corresponding author: Hosein Farzanehfard.) the same extra elements used to provide soft switching at turn
The authors are with the Department of Electrical and Computer Engi- OFF, are employed to replace the switch of current shaping stage
neering, Isfahan University of Technology, Isfahan 8415683111, Iran (e-mail:, [Fig. 1(a)]. As a result, a fully soft-switched PFC is obtained with
abasian@ieee.org; hosein@cc.iut.ac.ir; s.amir.hashemi@ec.iut.ac.ir). no additional switch, simple control system while no additional
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org. losses are imposed. Also, this converter has fewer elements
Digital Object Identifier 10.1109/TPEL.2019.2895116 when compared to its counterparts, but its boost inductor charge
0885-8993 © 2019 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications standards/publications/rights/index.html for more information.
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ABASIAN et al.: SINGLE-STAGE SINGLE-SWITCH SOFT-SWITCHING (S6) BOOST-FLYBACK PFC CONVERTER 9807
where D is the converter duty cycle, vin (t) and iin (t) respec-
tively denote the input voltage and current. Also Vo is the output
voltage and Ts is the switching period. The relation between vin
and iin depends on duty cycle and vin to vo ratio. Even if the
output voltage is assumed greatly higher than the peak of the
input voltage, the relation between vin and iin is nearly linear,
only if the duty cycle is fixed and then the converter would have
an inherent PFC property. Thus, if the charge time of the boost
inductor varies with time, then the relation between vin and iin
is not linear enough anymore which leads to intense amount of
Fig. 1. (a) S6 PFC converter of [13]. (b) Proposed S6 PFC converter. harmonic content. It should be noted that (1) is derived from
the inductor volt–second balance. In the converter of [13], the
time depends on the input voltage value and thus varies with the boost inductor is charged through a circuit which consists of a
input voltage amplitude. To lower the input-current THD, it is rectified input voltage source and Cr . Thus, the charge time of
preferred that the charge time of boost inductor be dependent LB depends on the input voltage and because the input voltage
only on the converter duty cycle [11]. is time variant, the charge time of the boost converter varies
To overcome the drawback of the S6 converter in [13], a new with time. This results in deformation of the input current with
S6 converter with fewer semiconductor elements is proposed increased THD. Also, as soft-switching and even PFC operation
in this paper. The harmonic content of the proposed converter of this converter depends on the input voltage (charging voltage
fulfills the IEC61000-3-2 class D harmonic current limits and is of the resonant capacitor), the performance would reduce no-
noticeably lower than that of the converter in [13]. The proposed ticeably by varying input voltage. To solve these problems, the
converter is fully soft-switched and also the leakage inductance circuit should be improved in such a way that the input inductor
energy is recovered to improve the converter efficiency. In ad- current is proportional to the switch ON time.
dition, the leakage inductance of the flyback transformer is em- To overcome the above-mentioned problem, a new S6 PFC
ployed as the resonant inductance while no extra switch is used. is proposed as illustrated in Fig. 1(b). In this converter, the
Furthermore, the switch zero voltage switching (ZVS) turn-OFF auxiliary winding (Na ) is connected in series with the boost
is resulted to eliminate the high voltage spike on switch at turn- inductor (LB ) to form a PFC cell together with the resonant
OFF instant which reduces losses, electromagnetic interference, capacitor (Cr ). This special connection of the auxiliary winding
and the switch voltage stress. A prototype of the proposed con- in addition to a proper design can result in the appropriate control
verter is implemented to verify the converter theoretical analysis of the input inductor voltage. Controlling the inductor voltage
and operation. would lead to controlling its charge and discharge states. Also
due to presence of bulk capacitor voltage (VC B ) in the charging
II. PROPOSED CONVERTER loop and its almost constant voltage, the effect of input voltage
variations on converter performance is reduced.
A. Description of the Idea
Fig. 1(b) illustrates the schematic of proposed converter.
B. Operating Principles
The converter consists of a boost inductor (LB ), dc-link ca-
pacitor (CB ), output capacitor (Co ), resonant capacitor (Cr ), In the proposed converter, both LB and Lm are designed to
power MOSFET (Sw), input bridge diode rectifier, high frequency operate under DCM condition. This would simplify the control
diodes (D1 , Do ), and a three-winding transformer (T ) where circuit by eliminating the current shaping control loop. The
Np , Ns , and Na denote the primary, secondary, and auxiliary proposed converter operating modes in one switching period are
windings number of turns respectively. To simplify the theoret- illustrated in Fig. 2 and the steady-state theoretical waveforms
ical analysis, it is assumed that all semiconductors components are shown in Fig. 3.
are ideal, the voltage of dc-link capacitor is almost constant and Stage 1 (t0 –t1 ): This mode starts when the switch is turned
also during a switching period, the input voltage is constant due ON under zero current switching (ZCS) due to DCM operation
to high switching frequency and low-line frequency. of the inductor LB and also the transformer leakage induc-
In the proposed S6 PFC, the auxiliary winding (Na ) is con- tance. Diodes D1 and Do are reversed biased and LB starts
nected in series with the boost inductor. This formation allows charging, while VC B is applied to Lm and causes the magnetiz-
controlling the boost inductor voltage and shaping its current ing inductance current (Im ) to increase linearly. Concurrently,
which results in lowering the THD. Also the auxiliary wind- Cr which has a negative initial voltage is being charged by
ing diode in [13] is eliminated in the proposed topology which the input inductor current and its voltage increases until it be-
improves the efficiency and simplifies the converter. comes equal to VC B at the t1 . The bulk capacitor current (IC B )
The input inductor (LB ) operates in DCM, similar to the can be obtained by the ampere-turns of transformer. The trans-
converter of [13] in order to have intrinsic PFC characteristic. former is modeled with an ideal transformer plus a magnetizing
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9808 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 34, NO. 10, OCTOBER 2019
inductance.
IC B = −(Im + (Na /Np )IL B ). (2)
The current of power switch is equal to sum of IC B and LB
current (Isw = IL B − IC B ). As discussed later, LB operates
under DCM condition and due to the transformer leakage in-
ductance, IC B gradually increases from zero, thus the switch
current slowly rises from zero which indicates ZCS operation
of the power switch as illustrated in Fig. 3.
Stage 2 (t1 –t2 ): This interval begins when D1 starts conduct-
ing and fixes the voltage across LB (VL B ) at a certain value
which can be obtained from the below equation
VL B = Vin + VN a − VC r = Vin + (Na /Np − 1)VC B . (3)
As discussed before, in the proposed converter, the aim is to
keep LB in charging mode till the switch turns OFF. To keep LB
in charging mode, its voltage must be positive regardless of the
input voltage value, thus at the worst case (Vin = 0)
(Na /Np − 1)VC B ≥ 0 ⇒ Na ≥ Np . (4)
Fig. 2. Topological operating modes of proposed converter. (a) Stage 1. It is not desired to choose Na > Np because it increases the
(b) Stage 2. (c) Stage 3. (d) Stage 4. (e) Stage 5. (f) Stage 6. (g) Stage 7. switch current stress and the transformer cost. For this reason,
choosing Na = Np is the most suitable case. The power switch
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ABASIAN et al.: SINGLE-STAGE SINGLE-SWITCH SOFT-SWITCHING (S6) BOOST-FLYBACK PFC CONVERTER 9809
current can be written as below Fig. 5. Input inductance voltage in one switching period.
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9810 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 34, NO. 10, OCTOBER 2019
VC B + |VC r 0 | Vin + VC B ( N
N p − 1)
a
d2 = d1 + D
2(VC B + N N s Vo − Vin )
a
VC B + N
N s Vo − Vin
a
(14)
where d1 T is time interval of Stage 1 (from switch turn ON to
diode D1 turn ON) which can be observed in Fig. 5. Solving (13)
and (14) simultaneously result in finding VC B and d2 . However,
the values of d1 and VC r 0 in (14) are still unknown and must
be determined. It is mentioned in Stage 1 that d1 Ts is the time
that the voltage of resonant capacitor rises from VC r 0 to VC B .
In this stage, VC r equation can be written as below with respect
to the initial conditions
Vin
d1 = fs LB Cr cos−1 . (16)
VC B + Vin + |VC r 0 |
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ABASIAN et al.: SINGLE-STAGE SINGLE-SWITCH SOFT-SWITCHING (S6) BOOST-FLYBACK PFC CONVERTER 9811
TABLE I
PROTOTYPE CIRCUIT ELEMENTS
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9812 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 34, NO. 10, OCTOBER 2019
Fig. 10. (a) Measured harmonic content of the input current under different
line voltages. (b) THD comparison. (c) Efficiency under different output powers
for different line voltages at 200-kHz operating frequency.
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ABASIAN et al.: SINGLE-STAGE SINGLE-SWITCH SOFT-SWITCHING (S6) BOOST-FLYBACK PFC CONVERTER 9813
TABLE II
DIFFERENT SOFT SWITCHING BOOST FLYBACK TOPOLOGIES COMPARISON
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