The 2022 International Future Energy Challenge (IFEC2022)

Student Competition

Presentation of Leibniz University Hannover IFEC Team

25.03.2022
Overview

Introduction of the Presentation of the DC-AC

team prototype conversion

Control System DC-DC

Roadmap until July
approach conversion

Team of Leibniz University Hannover IFEC 2022 Seite 2

 Team Prototype DC-AC DC-DC Simulation

Team of Leibniz University Hannover

Marie Hanemann
Tilo Teichert
Tobias Töllner
Meriem Khader
Artjom Dubinin
Lennart Hoffmann
Govind Sudheer
Lucas de Araujo
Vinicus Bezerra
Tobias Brinker
Tobias Manthey
Dr. Prof. Yoash Levron Mechatronics
Dr. Prof. Jens Friebe Electrical Engineering
Power Electronics

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 Team Prototype DC-AC DC-DC Simulation

System Overview

Interchangeable Panels
Interleaved Boost Converter High Voltage DC-Link for Grid Connection

Series Resonant Converter

Universal output
Inverter Stage

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 Team Prototype DC-AC DC-DC Simulation

Switching Panels

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 Team Prototype DC-AC DC-DC Simulation

Switching Panels
A: Three-Phase B: Single-Phase C: Single-Phase
Mode Mode Mode
208V – 260V 230V 120V

Totem-Pole Tripple
Modulation with double Interleaving
Interleaving

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 Team Prototype DC-AC DC-DC Simulation

Mainboard

• Three Half-Bridge modules

• Series resonant DC/DC converter
• Booster Module
• STM32 Controller

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 Team Prototype DC-AC DC-DC Simulation

Half-Bridge PCB

• GaN-Transistors: GS66504B (100mΩ, 650V)

• Isolated Gate Driver: SI8271
• Isolated Driver Supply

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 Team Prototype DC-AC DC-DC Simulation

DC-AC Conversion, Three-Phase Feedforward Control

Three-Phase Mode Lab Tests:

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 Team Prototype DC-AC DC-DC Simulation

DC-AC Conversion, Grid Coupled including PLL & Current Control

Single-Phase Active Power Lab Tests: Single-Phase Reactive Power Lab Tests:

110VRMS
110VRMS

200mA

200mA − 𝑗100mA

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 Team Prototype DC-AC DC-DC Simulation

(Interleaved) Boost Converter Prototype

Highlighted feature: Bypass Mode if Uin ≥ 48V for maximum efficiency at nominal
input voltage.
• Bypass Mode allows different voltage ratings of the high-side (60 V) and
low-side MOSFET (80 V)
• Optimization of the high-side MOSFET’s conduction losses

Interleaving (fixed 180° phase shift):

• Lower component stress
• Reduced input and output ripple
• Higher efficiency

Measurements:
• Efficiency in Bypass-Mode: 99.8%

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 Team Prototype DC-AC DC-DC Simulation

Series Resonance Converter

Highlighted feature: Transformer optimization to trade off efficiency,
cost, size and weight.
• Leakage inductance is used as resonant inductance to reduce size, ZVS ZCS

weight and costs

• Influence of individual parameter variation analyzed
• Elaborated through simulations and measurements

Proven topology of the SRC:

• Switching frequency is set slightly below resonance frequency
fsw < fres
• Turn-on ZVS on primary side, turn off ZCS on secondary side
• Gain obtained by the turn ratio of n = 8
• No additional control required

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 Team Prototype DC-AC DC-DC Simulation

Series Resonance Converter

Measurements:
• General conditions:
Input voltage Vin 48 V
Output voltage Vout 384 V
Output power Pout 500 W PQ 32/30 SPS, taken after 30 minutes at 500 W output power and natural convection.

Switching frequency fsw 500 kHz

Resonant frequency fres 520 kHz

Natural convection Tamb 22 ℃

• To achieve the target efficiency of 95% at

1kW, PQ 32/30 and SPS winding arrangement
is preferred

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 Team Prototype DC-AC DC-DC Simulation

Control System Approach

Active Power Test

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 Team Prototype DC-AC DC-DC Simulation

Roadmap until July

Final event

DC-DC PCB

Interleaved Boost
Converter

Transformer Design

Control
Time
Implementation Buffer
"The Wedding"
Commissioning of
Prototype

Grid Operation tests

incl. Services

Efficiency tests

February March April May June July

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 Team Prototype DC-AC DC-DC Simulation

Conclusion
 1) Manufacturing costs less than $200
 2) Capable of input voltage range from 30V to 60V
 3) Input current: Limited to 20 ADC, with ripple less than 10%
 4) Capable of output voltage range: single-phase 120~230VAC, and three-phase 208~260VAC
 5) Able to power the grid with the maximum power of 1kW
 6) Grid current total harmonic distortion (THD): less than 2% @1kW
 7) Grid power factor: >0.99 when only 1kW active power is demanded
 8) Overall solar-to-grid power efficiency: higher than 95% at 1kW and higher than 94% at 500W
 9) Active power delivery
 10) Reactive power compensation
 11) Basic protection  achieved
 achieved in Simulation

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Thank you for your attention!

25.03.2022
Series Resonant Converter
Winding arrangement of the transformer designs:
• Winding on the secondary side is kept the same for each design to evaluate the influence of different
primary windings
• PQ 32/30 with SP winding (left) and SPS • RM14 (left) and PQ 32/20 (right)
winding (right), 50 µm litz winding with 100 µm foil winding

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Series Resonance Converter

• 𝑓sw < 𝑓res : cap. operating point to achieve turn on ZVS on primary
side and turn off ZCS on secondary side.
• Boost with galvanic isolation.
• Resonance Capacitor on secondary side, due to size.
• Stray inductance is included in the Transformer.

[1]

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(Interleaved) Boost Converter
Measurements:
• Input voltage: 30 V Output voltage: 48 V Output power: 500 W Phase shift: 180°

VGS,Q2 VGS,Q4 VDS,Q1 IL1 IL2

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DC Link Capacitor Balancing Strategy [2]
Leakage currents cause an asymmetrical voltage distribution between series-connected electrolytic capacitors.
Balancing is required!
Tab. 1: Comparision of balancing methods
Resistive balancing Active balancing
Resistive Active
𝑉DC 400 V
𝑅B 4 k >4 k
𝜏 720 ms <720 ms
𝑃B 20.2 W 2W

Tab. 2: 500 V complementary MOSFETs

Type Comp. Price @500
N-CH FQD6N50CTM 0.84 $
P-CH FQB1P50TM 0.7 $

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Mainboard Dimensions

160mm
80mm

112,5mm
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Literature

• [1] Infineon application note, access: 03/23/2022, Link:

https://www.infineon.com/dgdl/Application_Note_Resonant+LLC+Converter+Operation+an
d+Design_Infineon.pdf?fileId=db3a30433a047ba0013a4a60e3be64a1
• [2] Hans Ertl, Thomas Wiesinger, Johann W. Kolar*, Franz C. Zach “A Simple Active Method
to Avoid the Balancing Losses of DC Link Capacitors”, 24th International Conference on
Power Electronics (PCIM), Nürnberg, Germany, May 20-22, 2003

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